Compositions for compounding, extrusion and melt processing of foamable and cellular halogen-free polymers

ABSTRACT

Described herein are foamable compositions and methods of making foamed compositions. The foamable composition comprises at least one polymer and a foaming agent. The foaming agent comprises a talc or a talc derivative. The polymers described herein comprise a substantially non-halogenated polymer. One or more additives are added to render the compositions flame retardant and/or smoke suppressant. Also described are Power over Ethernet (PoE) cables, having at least one electrical conduit comprising an electrically conductive core, an insulation that at least partially surrounds said electrically conductive core and a polymeric separator extending from a proximal end to a distal end and having at least one channel adapted for receiving the at least one electrical conduit. The PoE cables are capable of carrying about 1 watt to about 200 watts of power.

CROSS-REFERENCE TO RELATED APPLICATIONS

This Application is a continuation of U.S. patent application Ser. No.14/934,792, filed on Nov. 6, 2015, which claims the priority to and thebenefit of U.S. Provisional Application No. 62/076,736, filed on Nov. 7,2014. The entire teachings and disclosures of the earlier applicationsare incorporated herein by reference.

BACKGROUND OF INVENTION

A broad range of electrical cables and buffered optical fibers cablesare installed in modern buildings for a wide variety of uses. Thesecables are used, for example, to provide data transmission betweencomputers, voice communications, as well as control signal transmissionfor building security, fire alarms, and temperature control systems.Cable networks extend throughout modern office and industrial buildings,and frequently extend through the space between the dropped ceiling andthe floor above.

Ventilation system components are also frequently extended through thisspace for directing heated and chilled air to the space below theceiling and also to direct return air exchange. The space between thedropped ceiling and the floor above is commonly referred to as theplenum area. Electrical cables and fiber optic cables extending throughplenum areas are governed by special provisions of the National ElectricCode (“NEC”).

Because flame and smoke can travel along the extent of a plenum area inthe event of electrical fire, the National Fire Protection Association(“NFPA”) developed a standard to reduce the amount of flammable materialincorporated into insulated electrical conductors, fiber optic buffersand jacketing of cables. Reducing the amount of flammable material,according to the NFPA, would reduce the potential of insulation, fiberoptic buffering, and jacket materials to spread flames and smoke toadjacent plenum areas and potentially to more distant and widespreadareas in a building.

In 1975, the NFPA recognized the potential flame and smoke hazardscreated by burning cables in plenum areas and adopted in the NEC astandard for flame retardant and smoke suppressant cables. Thisstandard, commonly referred to as “the Plenum Cable Standard,” permitsthe use of a cable without a conduit, so long as the cable exhibits lowsmoke and flame retardant characteristics. The test method for measuringthese characteristics is commonly referred to as the Steiner TunnelTest. The Steiner Tunnel Test has been adapted for the burning of cablesaccording to the following test protocols: NFPA 262, UnderwritersLaboratories (“U.L.”) 910, or Canadian Standards Association (“CSA”)FT-6. The test conditions for each of the U.L. 910 Steiner Tunnel Test,CSA FT-6, and NFPA 262 are: a 300,000 BTU/hour flame is applied for 20minutes to 24-foot lengths of test cables mounted on a horizontal traywithin a tunnel. The criteria for passing the Steiner Tunnel Test are asfollows:

Flame Spread Requirement: less than 5 feet

Smoke Generation Requirements:

1. Maximum optical density of smoke less than 0.5

2. Average optical density of smoke less than 0.15 of fire retardantcabling

This standard is one of the most stringent test methods for residentialand commercial buildings. In plenum applications for voice and datatransmission, electrical conductors and cables should exhibit low smokeevolution, low flame spread, and favorable electrical properties to passthe stringent requirements of copper data cables. Category 5e cableshave evolved to provide even higher data transmission speeds with 10gigabit per second cables, which are now designated Categories (“Cat”)6, 6e and 6A. A Category 8, or a 40 gigabit per second cable, is beingdeveloped. Cables selected for plenum applications must exhibit abalance of properties and every component in a communications cable mustperform its role.

Separators, jackets, insulations, buffer tubes and blown fiber tubingused in cables that meet the electrical requirements of Categories 6 and7 must also pass the new norms for flammability and smoke generation.Tables 2 and 3, below, indicate categories for flame and smokecharacteristics and associated test methods as discussed herein.

Fiber optic cables and fiber optic blown tubing, which are used in theplenum areas of buildings, must adhere to the same flame retardancy andlow smoke characteristics of the NFPA 262 Plenum Test. UnderwritersLaboratory (UL 2885) is a test method for determining whether componentsor materials of a cable can be designated as a non-halogen cable.Underwriters Laboratory (UL 2885), titled Acid Gas, Acidity andConductivity of Combusted Materials and Assessment, uses IEC 60754-1,IEC 6074-2 and IEC 62821-1 to benchmark “all materials” within the cabledesign, i.e., insulation, spline or crosswebs, tapes or other cablefillers, fiber optic buffer and the overall jacket. Based on these testmethods, a determination can be made for the presence of halogens, e.g.,chlorine, bromine and fluorine. Test protocol 62821-1 Annex B,determines the presence of a halogen using the Sodium Fusion Procedureas described in Part 5.3 IEC 62821-2, i.e., Chemical Test: Determinationof Halogens—Elemental Test.

Materials evaluated to IEC 62821-1 Annex B Assessment of HalogensRequired for extruded material.

The test protocol consists of the following stages:

Stage 0: Determination of Halogens—elemental test for chlorine, bromineand fluorine using the sodium fusion procedure as described in part 5.3of IEC 62821-2 (Chemical Test: Determination of Halogens—ElementalTest). If the results for chlorine or bromine or fluorine are positive,proceed to Stage 1.

Stage 1: Test according to 6.2.1 of 60754-2 for pH and Conductivity. Ifthe pH is ≥4.3, the conductivity is >2.5 μS/mm and ≤10 μS/mm, proceed toStage 2.

Stage 2: Test according to 6.1.1 of 60754-1 for chlorine and brominecontent expressed as HCI. If the result if ≤0.5%, proceed to Stage 3.

Stage 3: Test for the determination of low levels of fluorine asdescribed in part 45.2 of IEC 60684-2 (Determination of low levels offluorine) Methods A (Ion selective electrode method fluoride) or B(Alizarin fluorine blue method).

The European standards have similar goals of fire retardant and lowsmoke generation cables. Polyvinylchloride, a halogenated material,remains a dominant jacketing grade throughout the European cablecommunity. The standards which have evolved are the so-calledInternational Classification and Flame Test Methodology forCommunications Cable. Based on these evolving standards, a new list ofacronyms has evolved, albeit with much similarity to the North Americanstandards.

These Euro-classes for cables measure the following:

A. Flame Spread = FS B. Total Heat Release = THR C. Heat Release Rate =HRR D. Fire Growth Rate = FIGRA E. Total Smoke Production = TSP F. SmokeProduction Rate = SPR

The European International Classification and Test Methodology forCommunication Cables is shown below in Table 1 and it is shown in anabbreviated form.

TABLE 1 The European International Classification and Test Methodologyfor Communication Cables Additional Class Test Methods ClassificationCriteria Classification A_(ca) EN ISO 1716 PCS ≤ 2.0 MJ/kg (1) Note:Mineral filled circuit integrity cable B1_(ca) EN 50399 FS ≤ 1.75 m andSmoke production (30 kW THR₁₂₀₀ ≤ 10 MJ (2, 5) and Flaming flamessource) and Peak HRR ≤ 20 kW droplets/particles and and FIGRA ≤ 120 Ws⁻¹(3) and Acidity EN 60332-1-2 H ≤ 425 mm (4, 7) B2_(ca) EN 50399 FS ≤ 1.5m and Smoke production (20.5 kW THR_(1200s) ≤ 15 MJ (2, 5) and Flamingflames source) and Peak HRR ≤ 30 kW droplets/particles and and FIGRA ≤1500 Ws⁻¹ (3) and Acidity EN 60332-1-2 H ≤ 425 mm (4, 7) C_(ca) EN 50399FS ≤ 2.0 m and Smoke production (20.5 kW THR_(1200s) ≤ 30 MJ (2, 6) andFlaming flames source) and Peak HRR ≤ 60 kW droplets/particles and andFIGRA ≤ 300 Ws⁻¹ (3) and Acidity EN 60332-1-2 H ≤ 425 mm (4, 7) D_(ca)EN 50399 THR_(1200s) ≤ 70 MJ Smoke production (20.5 kW and Peak HRR ≤400 kW (2, 6) and Flaming flames source) and FIGRA ≤ 1300 Ws⁻¹droplets/particles and (3) and Acidity EN 60332-1-2 H ≤ 425 mm (4, 7)E_(ca) EN 60332-1-2 H ≤ 425 mm F_(ca) No Performance Determined

Table 2, below, provides a listing and comparison of the North Americanstandards and the European standards from most stringent flameretardancy and low smoke requirements to least stringent.

TABLE 2 A comparison of North American & European Fire PerformanceStandards from most severe to least severe for Communications CablesNorth America North American European Test Standard European StandardTest Protocols Protocols Most Severe Plenum Test Class B1 SteinerTunnel - Class B1 30 KW UL 910 LAN Comm. 88 KW Flame Sources NFPA 262Cables 300 BTU @ 20 FS < 1.75 m, THR < FT-6 EN 50399-30 KW minutes plus10 mg CMP EN 60332-1-2 smoke peak <.5 Peak HRR < 20 KW Average <.15FIGRA < 120 WS Severe Riser Test Class C Riser Test - 154 KW Class C20.5 KW UL 1666 EN 50399- 527 KW @ 30 Flame Source FT-4 10..5 KW &minutes FS < 2.0 m TGR < 30 m; CMR EN60332-1-2 Peak HRR < 60 KW FIGRA <300 WS Less Severe General Class D General Purpose Class D 20.5 KWPurpose Tray IEC 60332-3 20.5 KW Flame Source Cable Test EN 50399- 70KBIT @ 20 THR < 70 m; UL 1581 20.5 KW minutes PEAK HRR < 400 KW FT-2/CMFIGRA 1300 WS Least Severe VW-1 Class E Bunsen Burner Class E FT-1 IEC60332-1 Test H < 425 mm 1 minute (15 seconds flame)

The use of halogens (e.g. fluoropolymers) in communications cables, suchas for insulation materials, crosswebs, tapes, tubes or cable fillers,and the use of low-smoke PVC jacket materials has been widespread incopper based and fiber based cables. Optimizing and meeting theelectrical requirements of copper communication cables, i.e., Cat 5e toCat 6A to Cat 8, without the use of materials comprising halogens, hasbeen the unsolved challenge for over three decades. The materials usedfor fiber optic buffers and jackets utilize similar halogenatedmaterials to reduce flame spread and smoke generation.

Communication cables conforming to NEC/CEC/IEC requirements arecharacterized by possessing superior resistance to ignitability,improved resistance to flame spread and lower levels of smoke generationduring fires than cables having lower fire ratings. Often theseproperties can be anticipated by measuring a Limited Oxygen Index (LOI)for the specific materials used to construct the cable. Conventionalcopper and fiber optic cable designs of data grade telecommunicationcables for installations in plenum chambers employ a halogenated lowsmoke polyvinylchloride (PVC) generating jacket material. For example, aconventional design may include a filled PVC formulation or afluoropolymer material surrounding a core of twisted conductor pairs,with each conductor individually insulated with a fluorinated-basedinsulation (e.g., fluorinated ethylene propylene (FEP)).

Recently, the development of “high-end” Category 6 and 7 cables hasincreased the need for fluorinated ethylene propylene (FEP),perfluoroalkoxy (PFA) and perfluoromethylalkoxy (MFA) that include powersum near end crosstalk (“NEXT”) and power sum equal level far endcrosstalk (“ELFEXT”) considerations along with attenuation, impedance,and attenuation crosstalk ratio (“ACR”) values in design of such cables.

Recent and proposed cable standards are increasing maximum frequenciessupported by the cables from 100-200 MHz to 250-1000 MHz Recently, 30Gbits of data over copper high-speed standards have been proposed. Themaximum upper frequency of a cable is that frequency at which theattenuation/cross-talk ratio (“ACR”) is approximately equal to 1. Sincesignal strength decreases with frequency data attenuation and cross-talkincreases with frequency, the design of cables that would support highfrequencies poses a significant challenge. This is especially true sincemany conventional designs for cable components, e.g., fillers andspacers, may not provide sufficient cross-talk isolation at the higherfrequencies.

The selection of materials for forming cables that can support highfrequencies and concurrently exhibit favorable flame and smokecharacteristics can be challenging. Fluorinated ethylene/propylenepolymers traditionally exhibit better electrical performance comparableto non-halogenated polyolefin polymers, such as polyethylene orpolypropylene. Polyethylene has favorable mechanical properties as acable jacket due to its tensile strength and elongation to break.However, polyethylene exhibits unfavorable flame and smokecharacteristics.

Limiting Oxygen Index (ASTM D-2863) (“LOI”) is a test to determine thepercent concentration of oxygen that will support flaming combustion ofa test material. The greater the LOI, the less susceptible a material isto burning. In the atmosphere, there is approximately 21% oxygen, so amaterial exhibiting an LOI of 22% or more cannot burn under ambientconditions. As pure polymers without flame retardant additives, membersof the polyolefin family, namely, polyethylene and polypropylene, havean LOI of approximately 19. Because of their LOI, these polyolefinsexhibit disadvantageous properties relative to flame retardancy in thatthey do not self-extinguish a flame, but rather propagate a flame with ahigh rate of heat release. Moreover, the burning melt can spread anddrip on surrounding areas, thereby further propagating the flame. Thesematerials could burn similarly to kerosene or gasoline when ignitedwhich is unacceptable for use in building plenum areas.

Table 3 below summarizes the electrical performance and flame retardancycharacteristics of several conventional polymeric materials. Besidesfluorinated ethylene/propylene, other commercially used melt extrudablethermoplastics generally do not provide a favorable balance ofproperties (i.e., high LOI, low dielectric constant, and low dissipationfactor). Moreover, when flame retardant and smoke suppressant additivesare included within such thermoplastic materials, the overall electricalproperties generally deteriorate.

TABLE 3 Fire Retardancy Characteristics for Copper Cabling and FiberOptic LAN Cables Electrical Properties Dielectric Dissipation ConstantFactor Material Type* 1 MHz, 1 MHz, (Flame Retardant Used) 23° C. 23° C.LOI %** PE (No Halogen) 2.2 0.0003 19 FRPE (Brominated) 2.6-3.0 0.00328-32 FEP (Fluorinated) 2.1 0.0003 >90  PVC (Chlorinated) 2.7-3.5 0.02432 RSFRPVC (Chlorinated) Reduced 3.2-3.6 0.018 39 Smoke Fire RetardantLSFRPVC (Chlorinated) 3.5-3.8 0.038-0.080 49 Low Smoke Fire Retardant*PE = polyethylene; FRPE = flame resistant polyethylene; FEP =fluorinated ethylene-propylene; PVC = polyvinyl chloride; RSFRPVC =reduced smoke flame retardant polyvinyl chloride; LSFRPVC = low smokeflame retardant polyvinyl chloride **LOI = Limiting Oxygen Index

In addition to the requirement of low smoke evolution and flameretardancy for plenum cables, there is a growing need for enhancedelectrical properties for the transmission of voice and data overtwisted pair cables. In this regard, standards for electricalperformance of twisted pair cables are set forth in theTelecommunications Industry Association (TIA) and American NationalStandards Institute (ANSI) in ANSI/TIA-568-C.2. Similarly, the standardsfor data transmission over optical fiber cables are covered inANSI/TIA-568-C.3.

A balance of properties or attributes is needed for each component(e.g., insulation, buffer, cable fillers, fiber optic strength member,fiber optic blown tubing and jacketing) within copper and fibercommunications cable so that it can meet the electrical performance ofcopper cabling or the transmission characteristics of fiber optic highspeed data cable and pass the NFPA 262 Flame and Smoke Requirements, theNFPA 259 flame requirements and similarly the European standards forClass B and Class C.

Optical fiber cables exhibit a set of needs that include uniquemechanical properties to prevent damage to the fragile glass fibers.These needs are evolving for hybrid copper and fiber designs, PassiveOptical Networks (PON) or Power over Ethernet (PoE). For instance, PoEwill generate more heat as it provides data transmission as well aspower to LED lighting, wireless interface points, cameras and isemployed in a wide range of other applications whereby temperaturecontrol systems and office automation will be accomplished remotely frominteractive phones and computer devices. These cables will requirehigher temperature rated polymers, e.g., 125° C. to 250° C. operatinguse temperatures. A direct current with up to 51 watts can be used overa single 4-pair cable if all 4 pairs of the category 5, 5e, 6 and 6A areenergized.

Power Over Ethernet (POE) relates to a system in which electrical powercan pass safely along with data on these Ethernet cables. IEEE 802.3 of−2003 standard provides up to 15.4 watts of DC power and can operatewith Category 3 cables at this low power requirement. IEEE 802.3 at−2009 standard also known as POE+ or POE plus provides 25.5 watts ofpower over Category 5 or higher with some vendors announcing that up to51 watts of power could be transmitted with higher temperatureperformance polymers as the insulation.

There remains a need for a communications cable that can operatereliably while minimizing or eliminating cross-talk between conductorswithin a cable or alien cross-talk between cables, and also a need forseparators for use in such telecommunications cables, while meeting thedesign criteria described above, such as having a temperature rating upto 200° C. or even 250° C. There also remains a need for acommunications cable that can provide low smoke generation and overallflame retardancy, e.g., as required by the NEC for use in plenum andriser areas of a building. Further, despite advances in fabricatingpolymeric foamed articles for use in cable design, there is still a needfor improved foamable and foamed compositions, and methods of theirfabrication, for use in cables, e.g., telecommunications cables.

SUMMARY OF THE INVENTION

In one aspect, the present invention relates to the use of a class ofnon-halogenated polymers, herein referred to as engineered resins, forfabricating various components of a cable, e.g., a telecommunicationscable, a Power over Ethernet (PoE) cable. It has been have discoveredthat talc and talc derivatives can be employed to foam such polymers,thus allowing great flexibility in forming cables that can meetstringent cabling standards. In some embodiments, such cables can besubstantially free of halogens. The teachings of the invention areapplicable to forming copper cables, fiber optic cables, and cables thatinclude both copper conductors and optical fibers, as well as PoEcables.

There are some differences between components of a copper cable andcomponents of a fiber optic cable. For example, copper cables haveinsulation, but fiber optic cables have buffers. Also, copper cables usetapes, separators (e.g., crosswebs or splines), shielding tapes andother extruded fillers to improve electrical performance. Fiber opticcables can use Kevlar and glass reinforcing rods to strengthen the coreof the cable based on the fragile characteristics of glass fiberespecially during cable installation. Glass fiber can be blown intoraceways or tubing that are referred to as blown optical fiber tubing.Both copper cables and fiber optic or blown fiber optic cables can alsorequire an overall jacket material.

One aspect of the invention described herein is the foaming of anengineered polymer, which can be in the form of a pellet or a so-calledfoamable pellet that foams during the extrusion process. The foaming ofthe polymer advantageously lowers the combustible footprint of theentire cable, e.g., they can reduce the plastic footprint for cabling ina building by 20% to 50%. Further, in some embodiments, the foamedcomponents can be substantially free of halogens.

Another aspect of the invention is the development of a non-halogencable that bridges the difference between the most stringent NorthAmerican standards for fire retardancy and the most stringent Europeanstandard.

In one aspect, the present invention provides a globally acceptednon-halogen copper communications cable, a non-halogen fiber optic cableand a non-halogen, blown fiber optic tubing or raceway design that meetsthe most stringent flame retardancy and low smoke requirement in NorthAmerica and the European community.

In another aspect, the invention provides non-halogen engineeredpolymers with enhanced fire retardancy and methods for foaming suchpolymers for both the most severe North American Plenum test andEuropean Class B1, as well as the severe North American Riser test andEuropean Class C applications.

As discussed in more detail below, the polymers and polymer blends ofthe present invention allow fabricating separators, wire insulation andcable jackets that can be used to form cables that meet the moststringent flammability and smoke generation requirements. Further, thepolymers and polymer blends of the present invention can be employed toform blown tubing for optical fibers.

In one aspect, the invention is directed to a foamable composition. Thefoamable composition comprises at least one polymer and a chemicalfoaming agent. In some aspects, the at least one polymer is anon-halogen foamable polymer. The polymer can comprise any ofpolyphenylenesulfide (PPS), polyetherimide (PEI), polysulfone (PSU),polypheylsulfone (PPSU), polyethersulfone (PES/PESU),polyetheretherketone (PEEK), polyaryletherketone (PAEK),polyetherketoneketone (PEKK), polyetherketone (PEK), or polyolefins suchas polyethylene (PE), polyproplylene (PP), cyclic olefin copolymer(COC), polycarbonate (PC), polyphenylene ether (PPE), liquid crystalpolymer (LCP), and/or combinations thereof. In some embodiments, thefoaming agent comprises talc or a talc derivative.

TABLE 4 List of Non-Halogen Polymers Dielectric Dissipation MaterialManufacturer Trade Name Sg Constant Factor LOI % COC TOPAS AdvancedTOPAS 1.02 2.35 10 kHz 0.00007 1 kHz 19 Polymers PEI SABIC Ultem ™ 1.273.15  1 kHz 0.0012  1 kHz 47 PEI LTL Color ColorFast 1.27 3.15  1 kHz0.0012  1 kHz 47 Copounders PSU Solvay UDEL ® 1.24 3.04 1 MHz 0.0060  1MHz 26 PSU BASF Ultrason 1.24 3.04 1 MHz 0.0060  1 MHz 26 PPSU SolvaySpecialty Radel ® 1.29 3.44 60 Hz 0.0076  1 MHz 38 Polymers PEEK SolvaySpecialty KetaSpire ® 1.30 3.07 1 MHz 0.0030  1 MHz 40 Polymers PES/PESUSolvay Specialty Veradel ® 1.37 3.54 1 MHz 0.0056  1 MHz 39 Polymers LCPCelanese Corp. Vectra ® 1.50 3.00 1 MHz 0.0180  1 MHz 44 PEKK ArkemaKepstan ™ 1.27 2.50 1 MHz 0.0007  1 kHz 38 PPS Chevron Phillips Ryton ®1.34 3.20 1 MHz 0.002   1 MHz 44 PPS Celanese Corp. FORTRON ® 1.4  4.601 MHz 0.0011  1 MHz 49 PC Bayer Makrolon ® 1.29 3.20 1 MHz 0.0090  1 MHz27 PPE Evonik VESTORAN ® 1.19 2.70 1 MHz 0.0018  1 MHz 29

In some embodiments, a foamable composition according to the presentteachings can comprise a combination ofstyrene-ethylene/butylene-styrene (SEBS) polymers and/or othercompatibilizers, as well as polyolefins and blends of all materialsherein described. All of these non-halogen materials may be chemicallyfoamed in accordance with the present teachings to lower the combustiblefootprint in cables used in buildings.

In some embodiments, a variety of organic and inorganic additives can beused to improve the electrical and/or flammability and smoke generationof the foamed articles fabricated according to the various embodimentsof the present teachings. An additive can enhance the fire retardancyand/or smoke suppressant characteristics of the articles describedherein. Some examples of such additives include nano-composites of clayand other inorganics such as ZnO, TiO₂, and nitrogen phosphorus basedfire retardants. In some embodiments, the additives can be in the formof nano-sized particles. Other examples include insulative orsemi-conductive Buckminster fullerenes and doped fullerenes of the C₆₀family, nanotubes of the same and the like, which offer uniqueproperties that allow for maintaining electrical integrity as well asproviding the necessary reduction in flame retardance and smokesuppression.

In one aspect of the foamable composition, the talc or talc derivativeconstitutes the only foaming agent present in the foamable composition.In other embodiments, in addition to talc or a talc derivative, otherchemical foaming agents, such as MgCO₃ and CaCO₃ can be present in thefoamable composition.

In some embodiments, the foamable composition is melt processable at anelevated temperature that is sufficient to cause the melting of the atleast one polymer and to cause the talc or talc derivative to foam,i.e., to cause decomposition of the talc or talc derivative so as togenerate gas for foaming the composition. For example, in someembodiments, the foamable composition is melt processable at atemperature of at least about 600° F. In another embodiment, thefoamable composition is melt processable at a temperature of at leastabout 610° F. In another embodiment, the foamable composition is meltprocessable at a temperature of at least about 620° F. In anotherembodiment, the foamable composition is melt processable at atemperature of at least about 630° F. In another embodiment, thefoamable composition is melt processable at a temperature of at leastabout 640° F. In another embodiment, the foamable composition is meltprocessable at a temperature of at least about 650° F. In anotherembodiment, the foamable composition is melt processable at atemperature of at least about 660° F.

In one embodiment of the foamable composition, the talc or talcderivative comprises about 1% to about 50% by weight of said foamablecomposition. In another embodiment of the foamable composition, the talcor talc derivative comprises about 2% to about 40% by weight of saidfoamable composition. In another embodiment of the foamable composition,the talc or talc derivative comprises about 3% to about 30% by weight ofsaid foamable composition. In another embodiment of the foamablecomposition, the talc or talc derivative comprises about 4% to about 20%by weight of said foamable composition. In another embodiment of thefoamable composition, the talc or talc derivative comprises about 5% toabout 10% by weight of said foamable composition.

In one embodiment of the foamable composition, the at least one polymercomprises at least about 10% by weight of said foamable composition. Byway of example, the at least one polymer can comprise about 10% to about80% by weight of said foamable composition. In one embodiment of thefoamable composition, the at least one polymer comprises at least about20% by weight of said foamable composition. In another embodiment of thefoamable composition, the at least one polymer comprises at least about30% by weight of said foamable composition. In another embodiment of thefoamable composition, the at least one polymer comprises at least about40% by weight of said foamable composition. In another embodiment of thefoamable composition, the at least one polymer comprises at least about50% by weight of said foamable composition. In another embodiment of thefoamable composition, the at least one polymer comprises at least about60% by weight of said foamable composition. In another embodiment of thefoamable composition, the at least one polymer comprises at least about70% by weight of said foamable composition. In another embodiment of thefoamable composition, the at least one polymer comprises at least about80% by weight of said foamable composition.

In one aspect, the invention is directed to a foamed article made by aprocess comprising heating a foamable composition according to thepresent teachings to an elevated temperature (e.g., at least about 600°F.) sufficient to cause melting of at least one polymeric component ofthe foamable composition and to cause the talc or talc derivativepresent in the foamable composition to foam. The foamable compositioncan comprises one or more of the following polymers:polyphenylenesulfide (PPS), polyetherimide (PEI), polysulfone (PSU),polypheylsulfone (PPSU), polyethersulfone (PES/PESU),polyetheretherketone (PEEK), polyaryletherketone (PAEK),polyetherketoneketone (PEKK), polyetherketone (PEK), or polyolefins suchas polyethylene (PE), polyproplylene (PP), cyclic olefin copolymer(COC), polycarbonate (PC), polyphenylene ether (PPE), liquid crystalpolymer (LCP), and/or combinations thereof. The foamable composition canfurther comprise talc or talc derivative.

In one embodiment, the above foamed article is formed by heat processinga foamable composition according to the present teachings, whichcomprises talc or talc derivative at a concentration of about 1% toabout 20% by weight of the foamable composition. In another embodiment,the talc or the talc derivative comprises about 5% to about 10% byweight of the foamable composition. In an embodiment, the talc or thetalc derivative constitutes the only foaming agent in the foamablecomposition.

In an embodiment of the foamed article, the foamed article has a tensilestrength of about 2,500 psi to about 10,000 psi. Further, in anembodiment, the foamed article has a specific gravity of about 0.60 toabout 1.45 g/cm³.

In some embodiments, the foamed article is substantially free ofhalogens. In some embodiments, the foamed article is a non-halogenfoamed article. In another embodiment, the foamed article is anon-halogen foamed article defined by the UL 2885 protocol.

In some embodiments, the foamed article can comprise foamed cells havinga maximum dimension (e.g., a diameter) in a range of about 0.0005 inchesto about 0.003 inches. In some cases, the foamed cells can have anaverage diameter of about 0.0008 inches. The foamed cells can have aclosed cell structure, an open cell structure, or a combination thereof.In some embodiments, a majority of the foamed cells (e.g., greater than50%) have a closed cell structure. For example, greater than 50%,greater than 60%, greater than 70%, greater than 80% or greater than 90%of the foamed cells have a closed cell structure. Another embodimentincludes using talc as chemical foaming agent to form uniform cellstructures in the foamed or blown composition.

In one aspect, the present teachings are directed to a communicationscable (e.g., electrical and/or fiber optic), which comprises a separatorproviding a plurality of channels, each of which can receive anelectrical conductor and/or glass fiber. Typically, a twisted pair ofconductors is disposed in each of the channels. In some embodiments,there are 1, 2, 3, 4, 5, 6 or more channels. In another embodiment, oneor more fiber optic channels are also present in the communicationscable. The electrical conductor can include an electrically conductivecore (e.g., an electrically conductive element formed, e.g. of copper)and an insulation that at least partially surrounds the conductive core.

In some embodiments the separator comprises any of polyphenylenesulfide(PPS), polyetherimide (PEI), polysulfone (PSU), polypheylsulfone (PPSU),polyethersulfone (PES/PESU), polyetheretherketone (PEEK),polyaryletherketone (PAEK), polyetherketoneketone (PEKK),polyetherketone (PEK), or polyolefins such as polyethylene (PE),polyproplylene (PP), cyclic olefin copolymer (COC), polycarbonate (PC),polyphenylene ether (PPE), liquid crystal polymer (LCP), and/orcombinations thereof.

In some such embodiments, the separator can have a foamed structure. Forexample, the separator can have a cellular structure characterized by aplurality of cells (e.g., filled with a gas such as air) distributedtherein. As discussed in more detail below, such cellular structure canimprove the electrical and/or thermal properties of the foamed article.By way of example, the separator can exhibit a foaming level in a rangeof about 10% to about 80%, e.g., in a range of about 15% to about 70%,or in a range of about 20% to about 60%, or in a range of about 25% toabout 50%, or in a range of about 30% to about 40%. In some embodiments,the foaming level is about 10%, about 15%, about 20%, about 25%, about30%, about 35%, about 40%, about 45%, about 50%, about 55%, about 60%,about 65%, about 70%, about 75%, or about 80%.

In other embodiments, the separator can comprise the above polymers andcan be formed as a solid structure. Further, in some embodiments, theseparator can be substantially free of any halogen.

In some embodiments, the separator can include an additive distributedtherein. In some cases, the additive can be a smoke suppressant additiveand/or flame retardant additive. By way of example, the additive can byany of the molybdate derivatives, such as molyoxide, ammoniumoctamolybdate (AOM), calcium molybdate and zinc molybdate, metal oxides,such as Ongard II, zinc and other oxides, borates, such as zinc borateand meta borate, stannates, such as zinc hydroxyl stannates and zincstannates, nitrogen-phosphorus, phosphorus based esters, such astriaryl, tri aklkyl, and/or magnesium hydrates/carbonates, such asmagnesium hydroxide, magnesium carbonate, and antimony trioxide,decachlorodiphenyloxide, alumina trihydrate, and calcium carbonate.

In some embodiments, an insulation, which at least partially surroundsthe electrically conductive core of an electrical conductor is provided,which comprises any of polyphenylenesulfide (PPS), polyetherimide (PEI),polysulfone (PSU), polypheylsulfone (PPSU), polyethersulfone (PES/PESU),polyetheretherketone (PEEK), polyaryletherketone (PAEK),polyetherketoneketone (PEKK), polyetherketone (PEK), or polyolefins suchas polyethylene (PE), polyproplylene (PP), cyclic olefin copolymer(COC), polycarbonate (PC), polyphenylene ether (PPE), liquid crystalpolymer (LCP), and/or combinations thereof.

In some such embodiments, the insulation can have a foamed structure,while in other embodiments the insulation can have a solid structure. Insome embodiments, the insulation can include a multi-layer (e.g., abi-layer) structure in which different layers can comprise differentpolymers. In some such embodiments, one layer can have a solid structureand an adjacent layer can have a foamed structure. In anotherembodiment, both layers can have a foamed structure. By way of example,one layer can be formed as a solid structure comprising polyolefin, andan adjacent layer can comprise polyetheretherketone (PEEK) and can havea foamed structure. For example, the insulation can have a bi-layerstructure in which an inner layer (i.e., the layer in contact with theconductive core of the electrical conductor) is a solid layer and anouter layer (i.e., a layer disposed on the inner layer) is a foamedlayer. Alternatively, the inner layer can be a foamed layer and theouter layer can be a solid layer. Yet in other embodiments, both theinner and the outer layers are foamed layers.

In one aspect of the communications cable, the inner layer comprises afoamed layer with a foaming level of about 10% to about 80%, e.g., in arange of about 15% to about 70%, or in a range of about 20% to about60%, or in a range of about 25% to about 50%, or in a range of about 30%to about 40%. In some embodiments, the foaming level is about 10%, about15%, about 20%, about 25%, about 30%, about 35%, about 40%, about 45%,about 50%, about 55%, about 60%, about 65%, about 70%, about 75%, orabout 80%.

In some embodiments, the insulation can have a bi-layer structure inwhich any of the inner and/or the outer layer comprises at least oneadditive. In some embodiments, the additive can be a smoke suppressantand/or flame retardant additive. For example, the additive can be any ofmolybdate derivatives, such as molyoxide, ammonium octamolybdate (AOM),calcium molybdate and zinc molybdate, metal oxides, such as Ongard II,zinc and other oxides, borates, such as zinc borate and meta borate,stannates, such as zinc hydroxyl stannates and zinc stannates,Nitrogen-Phosphorus, phosphorus based esters, such as triaryl, triaklkyl, and ADP, and magnesium hydrates/carbonates, such as magnesiumhydroxide, magnesium carbonate, and antimony trioxide,decachlorodiphenyloxide, and alumina trihydrate.

In some embodiments, the insulation can be substantially free of anyhalogen.

In some embodiments, the communications cable can further include ajacket that at least partially encloses the separator and one or moreelectrical conductors that are disposed in the channels provided by theseparator. In some embodiments, the jacket can comprise any ofpolyphenylenesulfide (PPS), polyetherimide (PEI), polysulfone (PSU),polypheylsulfone (PPSU), polyethersulfone (PES/PESU),polyetheretherketone (PEEK), polyaryletherketone (PAEK),polyetherketoneketone (PEKK), polyetherketone (PEK), or polyolefins suchas polyethylene (PE), polyproplylene (PP), cyclic olefin copolymer(COC), polycarbonate (PC), polyphenylene ether (PPE), liquid crystalpolymer (LCP), and/or combinations thereof.

In some embodiments, the communications cable is substantially free ofany halogen. For example, the communications cable can include aseparator that is substantially free of any halogen. Further, theinsulation of the electrical conductors (e.g., twisted pairs) disposedin the channels provided by the separator is substantially free of anyhalogen. In addition, the jacket of the cable is substantially free ofany halogen.

In some embodiments, the compositions and communication cables describedherein comprise an engineered resin (e.g., a non-halogenated polymer)and a plurality of electrically conductive elements distributed withinthe engineered resin. At least some of the electrically conductiveelements can be formed at least partially of a metal.

In this embodiment and in other embodiments disclosed herein, theelectrically conductive elements can comprise any of a metal, a metaloxide, or other electrically conductive materials, such as carbonnanotubes, carbon fibers, nickel coated carbon fibers, single ormulti-wall graphene, or copper fibers, C₆₀ fullerene, among others. Byway of example, in some embodiments, the electrically conductiveinclusions include any of silver, aluminum, copper, gold, bronze, tin,zinc, iron, nickel, indium, gallium, or stainless steel. In someembodiments, the electrically conductive inclusions can include metalalloys, such as tin alloys, gallium alloys, or zinc alloys. In otherembodiments, the electrically conductive inclusions can include metaloxides, such as copper oxide, bronze oxide, tin oxide, zinc oxide,zinc-doped indium oxide, indium tin oxide, nickel oxide, or aluminumoxide. In some embodiments, some of the electrically conductiveinclusions are formed of one material while others are formed of anothermaterial. Further, in some embodiments, the electrically conductiveinclusions are formed of metals and are substantially free of any metaloxides, e.g., metal oxides form less than 5% of the inclusions.

In some embodiments, a weight ratio of the conductive elements to theone or more engineered resins can be in a range of about 1% to about30%. In some embodiments the electrically conductive elements compriseat least about 5% by weight of the composition, at least about 7% byweight of the composition, at least about 10% by weight of thecomposition, at least about 15% by weight of the composition, at leastabout 20% by weight of the composition, or at least about 25% by weightof the composition.

In some embodiments, the electrically conductive elements can also havea plurality of different shapes. For example, a first plurality of theconductive elements can have needle-like shapes and a second pluralityof the conductive elements can have flake-like shapes (e.g., rectangularshapes).

In some embodiments, at least some of the conductive elements can beformed of a metal. In some embodiments, the metal can include, withoutlimitation, any of silver, aluminum, copper, gold, bronze, tin, zinc,iron, nickel, indium, gallium, and stainless steel.

In some embodiments, at least some of the conductive elements can beformed of a metal oxide. In some embodiments, the metal oxide caninclude, without limitation, any of copper oxide, bronze oxide, tinoxide, zinc oxide, zinc-doped indium oxide, indium tin oxide, nickeloxide, and aluminum oxide.

In some embodiments, the conductive elements can include a plurality ofmetallic particles having an average particle size in a range of about 1micron to about 6000 microns. For example, the conductive elements canhave an average particle size in a range of about 10 microns to about 50microns, or in a range of about 50 microns to about 500 microns, or in arange of about 500 microns to about 1000 microns.

In another aspect, the compositions and communication cables disclosedherein, which comprises at least one engineered resin, a plurality ofelectrically conductive elements distributed within the at least oneengineered resin, and a chemical foaming agent distributed within the atleast one engineered resin. In some embodiments, at least a portion ofthe electrically conductive elements is formed of a metal. In someembodiments, the electrically conductive elements can have a pluralityof different shapes. For example, a first plurality of the conductiveelements have needle-like shapes and a second plurality of theconductive elements have flake-like shapes, e.g., rectangular shapes. Insome embodiments, a first plurality of the conductive elements have ashape primarily configured to reflect electromagnetic radiation in arange of about 1 MHz to about 40 GHz. In some embodiments, a secondplurality of the conductive elements have a shape primarily configuredto dissipate electromagnetic radiation in a range of about 1 MHz toabout 40 GHz.

In some embodiments, the electrically conductive elements comprise aplurality of fibrils. In some embodiments, the fibrils include a metal.In some embodiments, the metal comprises any of silver, aluminum,copper, gold, bronze, tin, zinc, iron, nickel, indium, gallium, andstainless steel. In some embodiments, the fibrils include a metal oxide.In some embodiments, the metal oxide comprises any of copper oxide,bronze oxide, tin oxide, zinc oxide, zinc-doped indium oxide, indium tinoxide, nickel oxide, and aluminum oxide.

In one aspect, the invention is directed to a method of manufacturing afoamed article. The method comprises processing a foamable composition,which comprises at least one of polyphenylenesulfide (PPS),polyetherimide (PEI), polysulfone (PSU), polypheylsulfone (PPSU),polyethersulfone (PES), polyetheretherketone (PEEK), polyaryletherketone(PAEK), or polyolefins such as polyethylene (PE), polyproplylene PP,cyclic olefin copolymer (COC), polyetherketone (PEK), polycarbonate(PC), polyphenylene ether (PPE), liquid crystal polymer (LCP), and/orcombinations thereof, and talc or talc derivative blended with thepolymer, at an elevated temperature so as to cause melting of thepolymer and decomposition of talc or talc derivative to generate gas,where the gas causes foaming of the melted composition.

In some embodiments of the above method for manufacturing a foamedarticle, the at least one polymer comprises about 10% to about 80% byweight of said foamable composition. In some embodiments, the at leastone polymer comprises about 30% to about 60% by weight of said foamablecomposition. In some embodiments, the at least one polymer comprisesabout 40% to about 55% by weight of said composition. In someembodiments, the at least one polymer comprises about 45% to about 50%by weight of said composition. In some embodiments, the at least onepolymer comprises about 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%,60%, 65%, 70% or 75%.

In some embodiments of the above method for manufacturing the foamedarticle, the talc or talc derivative comprises about 1% to about 50% byweight of said foamable composition. In some embodiments, the talc ortalc derivative comprises about 2% to about 40% by weight of saidfoamable composition. In some embodiments, the talc or talc derivativecomprises about 3% to about 30% by weight of said foamable composition.In some embodiments, the talc or talc derivative comprises about 4% toabout 20% by weight of said foamable composition. In some embodiments,the talc or talc derivative comprises about 5% to about 10% by weight ofsaid foamable composition. In some embodiments, the talc or talcderivative comprises about 6% to about 8% by weight of said foamablecomposition. In some embodiments, the talc or talc derivative is theonly foaming agent in the foamable composition.

In some embodiments of the above method of manufacturing a foamedcomposition, the resultant foamed composition comprises a tensilestrength of about 2,000 psi to about 10,000 psi. In some embodiments,the foamed article can be a separator, e.g., a separator suitable foruse in a telecommunications cable, an insulation for an electricalconductor, or a jacket for a cable, e.g., a telecommunications cable.

In one embodiment, the processing of the foamable composition isperformed by heating the foamable composition at a temperature of atleast about 600° F. In another embodiment, the foamable composition isheated to a temperature of at least about 610° F., at least about 620°F., at least about 630° F., at least about 640° F., at least about 650°F., or at least about 660° F.

In one embodiment, the processing of the foamable composition isperformed without employing gas injection. In other words, theprocessing of the foamable composition is performed without injectinggas from an external source into the molten composition. In suchembodiments, the foaming of the composition to generate the foamedarticle is achieved only via chemical foaming, e.g., via decompositionof talc or talc derivative present in the foamable composition. Inanother embodiment, gas injection is employed in addition todecomposition of talc or talc derivative to generate the foamed article.

In some embodiments, the present invention is directed to a Power overEthernet (PoE) cable. The PoE cable can comprise at least one electricalconduit comprising an electrically conductive core, an insulation thatat least partially surrounds said electrically conductive core, and apolymeric separator extending from a proximal end to a distal end andhaving at least one channel adapted for receiving the at least oneelectrical conduit.

In some embodiments, the at least one electrical conduit in the PoEcable is capable of transmitting telecommunications data and carryingelectrical power in a range of about 1 watt to about 25 watts.

In some embodiments, at least one of said insulation and said separatorof the PoE cable comprises at least one foamed polymer. For example, theat least one foamed polymer can be substantially free of halogen. Insome embodiments, the polymer is selected from the group consisting ofpolyphenylenesulfide (PPS), polyetherimide (PEI), polysulfone (PSU),polypheylsulfone (PPSU), polyethersulfone (PES/PESU),polyetheretherketone (PEEK), polyaryletherketone (PAEK),polyetherketoneketone (PEKK), polyetherketone (PEK), or polyolefins suchas polyethylene (PE), polyproplylene (PP), cyclic olefin copolymer(COC), polycarbonate (PC), polyphenylene ether (PPE), liquid crystalpolymer (LCP), and combinations thereof. In some embodiments, thepolymer comprises about 10% to about 80% by weight of said foamedpolymer.

In some embodiments, the separator of the PoE cable can further comprisea fiber-optic channel for receiving an optical fiber cable. In someembodiments, an optical fiber is disposed in said fiber-optic channel.In some embodiments, the separator can include four or more (e.g., 4, 5,6, 7, 8, 9, 10 or more) channels.

In some embodiments, the PoE cable further comprises a polymeric jacketsurrounding said electrical conduit and the polymeric support element,said jacket being substantially free of halogens. In some embodiments,the jacket has a tensile strength of about 2,000 psi to about 10,000psi.

In some embodiments, the insulation can further comprise an additive.For example, the additive can comprise at least one smoke suppressantadditive, at least one flame retardant additive, or a combinationthereof

There are a wide range of applications for the compositions describedherein, including the wire & cable, automotive, medical, filtration, oiland gas, and other industrial industries.

BRIEF DESCRIPTION OF THE DRAWINGS

Features and advantages of the claimed subject matter will be apparentfrom the following description of embodiments consistent therewith,which the description should be considered in conjunction with theaccompanying drawings.

FIG. 1 illustrates a hierarchy of high performance engineering resins.

FIG. 2A depicts a cross-sectional view of a foamed separator accordingto an embodiment of the invention.

FIG. 2B depicts a longitudinal view of the foamed separator of FIG. 2A.

FIG. 3A depicts a cross-sectional view of a foamed separator and acenter channel disposed in the separator according to another embodimentof the invention.

FIG. 3B depicts a longitudinal view of the center channel of FIG. 3A.

FIG. 4 illustrates a communications cable in accordance with anembodiment of the invention.

FIG. 5 illustrates another communications cable in accordance with anembodiment of the invention.

FIG. 6 schematically depicts a cross-sectional view of a separator and aplurality of conductors disposed in longitudinal channels provided bythe separator in accordance with an embodiment of the invention.

FIG. 7 schematically depicts a cross-sectional view of one embodiment ofan electrical conduit in accordance with an embodiment of the invention.

FIG. 8 schematically depicts a cross-sectional view of anotherembodiment of an electrical conduit in accordance with an embodiment ofthe invention.

FIG. 9 schematically depicts a cross-sectional view of a twisted pair inaccordance with an embodiment of the invention.

FIG. 10 illustrates a tape in accordance with an embodiment of theinvention.

FIG. 11 schematically depicts a cross-sectional view of a tight bufferin accordance with an embodiment of the invention.

FIG. 12 schematically depicts a cross-sectional view of a plurality oftight buffers disposed in a jacket in accordance with an embodiment ofthe invention.

FIG. 13 schematically depicts a cross-sectional view of a loose bufferwith a co-extruded inner surface in accordance with an embodiment of theinvention.

FIG. 14 schematically depicts a cross-sectional view of a plurality ofloose buffers with co-extruded inner surfaces, wrapped in tape, anddisposed in a jacket in accordance with an embodiment of the invention.

FIG. 15 illustrates a Power over Ethernet 4-pair copper cable with twofiber channels embedded within a crossweb design for plenum and riserapplications comprising non-halogen materials.

FIG. 16 illustrates a Power over Ethernet 8-pair copper cable with twofiber channels embedded within a crossweb design for plenum and riserapplications comprising non-halogen materials.

FIG. 17A illustrates a Power over Ethernet 4-pair copper cable havingfive slots (channels) with the fifth slot comprising two nested fiberoptic cables.

FIG. 17B illustrates a Power over Ethernet 4-pair copper cable having afoamed separator with five channels with the fifth channel comprisingtwo nested fiber optic cables for plenum and riser applicationscomprising non-halogen materials.

FIG. 17C illustrates a Power over Ethernet 4-pair copper cable forplenum and riser applications comprising non-halogen materials inaccordance with an embodiment of the invention.

FIG. 18A illustrates an embodiment of a Power over Ethernet 4-paircopper cable having five channels with one channel having two fiberoptic cables for plenum and riser applications.

FIG. 18B schematically depicts a cross-sectional view of a separator anda plurality of conductors and fiber optic cables disposed inlongitudinal channels provided by the separator in accordance with anembodiment of the invention.

FIG. 18C schematically depicts a cross-sectional view of a foamedseparator and a plurality of conductors and fiber optic cables disposedin longitudinal channels provided by the separator in accordance with anembodiment of the invention.

FIG. 18D schematically depicts a cross-sectional view of a foamedseparator and a plurality of conductors and fiber optic cables disposedin longitudinal channels provided by the separator in accordance with anembodiment of the invention.

FIG. 19A illustrates an embodiment of a Power Over Ethernet 4-paircopper cable having five channels with one channel having two fiberoptic cables for plenum and riser applications.

FIG. 19B schematically depicts a cross-sectional view of a separator anda plurality of conductors and fiber optic cables disposed inlongitudinal channels provided by the separator in accordance with anembodiment of the invention.

FIG. 19C schematically depicts a cross-sectional view of a separator anda plurality of conductors having foamed insulation and fiber opticcables disposed in longitudinal channels provided by the separator inaccordance with an embodiment of the invention.

FIG. 20 schematically depicts a cross-sectional view of four twistedpairs surrounded by tape in accordance with an embodiment of theinvention.

FIG. 21 is a flow chart of a method of manufacturing a tape inaccordance with an embodiment of the invention.

FIG. 22 schematically depicts a plurality of pellets according to anembodiment of the invention.

FIG. 23A schematically depicts a separator having a metal coatingdisposed on an external surface thereof according to an embodiment ofthe invention.

FIG. 23B schematically depicts a separator having a patchwork of metalportions disposed on an external surface thereof according to anembodiment of the invention.

FIG. 24 schematically depicts a separator having an electricallyconductive strip disposed therein according to an embodiment of theinvention.

FIG. 25 is a cross-sectional view of a cross-shaped separator withrifled or “saw-blade” like members according to an embodiment of theinvention.

FIG. 26 is a cross-sectional view of an asymmetric cross-shapedseparator with rifled or “saw-blade” like members according to anembodiment of the invention.

FIG. 27 is a cross-sectional view of a symmetrically shaped separatorwith rifled like members and a plurality of conductors disposed inlongitudinal channels provided by the separator in accordance with anembodiment of the invention.

FIG. 28A is a cross-sectional end view of an anvil-shaped separatorhaving slotted rifled sections.

FIG. 28B is a cross-sectional view of a separator with rounded regionsat the end of each anvil section.

FIG. 29 is a top-right view of one embodiment of the cable and separatorthat includes an anvil-shaped separator and a smooth/ribbed jacket.

DETAILED DESCRIPTION OF THE INVENTION

Certain exemplary embodiments will now be described to provide anoverall understanding of the principles of the structure, function,manufacture, and use of the compositions, devices, and methods ofproducing and making the communication cables disclosed herein. One ormore examples of these embodiments are illustrated in the accompanyingdrawings. Those skilled in the art will understand that the cables,cable components and methods of making the same specifically describedherein and illustrated in the accompanying drawings are non-limitingexemplary embodiments and that the scope of the present invention isdefined solely by the claims. The features illustrated or described inconnection with one exemplary embodiment may be combined with thefeatures of other embodiments. Such modifications and variations areintended to be included within the scope of the present invention.

So that the invention may more readily be understood, certain terms arefirst defined.

As used herein, the terms “about” or “approximately” for any numericalvalues or ranges indicate a suitable dimensional tolerance that allowsthe composition, part, or collection of elements to function for itsintended purpose as described herein. These terms indicate at most a ±5%variation about a central value.

The term “cross-talk” is used herein consistent with its common usage inthe art to refer to electromagnetic interference between conductors,cables, or other electronic circuit elements.

The term “engineered resin” or “engineering polymer” as used hereinrefers to any of the following polymers: polyphenylenesulfide (PPS),polyetherimide (PEI), polysulfone (PSU), polypheylsulfone (PPSU),polyethersulfone (PES/PESU), polyetheretherketone (PEEK),polyaryletherketone (PAEK), polyetherketoneketone (PEKK),polyetherketone (PEK), or polyolefins such as polyethylene (PE),polyproplylene (PP), cyclic olefin copolymer (COC), polycarbonate (PC),polyphenylene ether (PPE), liquid crystal polymer (LCP), and/orcombinations thereof.

The term “fibril” as used herein refers to a small slender filamenthaving a length equal or less than about 200 microns and an aspect ratiodefined as a ratio of length to width that is equal to or greater thanabout 100.

The term “electrically conductive material” as used herein refers to amaterial that exhibits an electrical surface resistivity less than about50 ohms per square or a volume resistivity less than about 40 ohms-cm.

The term “inclusion” as used herein refers to a material that is atleast partially contained within another material.

The term “needle-like” as used herein refers to the art recognized useof the term for a shape having a high aspect ratio, e.g., an aspectratio greater than about 75.

The term “flake-like” as used herein refers to the art recognized use ofthe term for any polygonal shape.

The term “talc” is used herein consistent with its common usage in theart to refer to any natural or synthetic minerals with the chemicalformula MgSiOH, H₂Mg₃(SiO₃)₄, Mg₃Si₄O₁₀(OH)₂, 3MgO.4SiO₂.H₂O, orMgOH.H₂O.SiOH. The term “talc derivative” is used herein to refer to“talc” that includes additives or impurities such as, for example,dolomite (a magnesium calcium carbonate), chlorite (a magnesium aluminumsilicate), magnesite (a magnesium carbonate), and calcium carbonate.Additives and/or impurities can be present as one or more minorcomponents with talc, for example, each additive or impurity cancomprise less than 1% (by weight), less than 2%, less than 3%, less than4%, less than 5%, less than 6%, less than 7%, less than 8%, less than9%, or less than 10% or more.

A “talc derivative” can also include other magnesium compounds, such as,for example, hydrotalcite. Hydrotalcite (Mg₆Al₂CO₃(OH)_(16‘·)4(H₂O)) canbe natural or synthetic. An example of a synthetic hydrotalcite can befound in U.S. Pat. No. 5,075,087, the entirety of which is herebyincorporated by reference. Hydrotalcite mineral data can be foundonline, for example at: http://webmineral.com/data/Hydrotalcite.shtml#.VGt_u_nF-e5. Hydrotalcite is a layered double hydroxide whose name isderived from its resemblance with talc and its high water content. Thelayers of the structure may stack in different ways, to produce a3-layer rhombohedral structure (3R Polytype), or a 2-layer hexagonalstructure (2H polytype). The two polytypes are often intergrown. Thecarbonate anions that lie between the structural layers are weaklybound, so hydrotalcite has anion exchange capabilities.

As used herein, the term “melt-processable” is meant that the polymercan be processed (i.e. fabricated into shaped articles, insulation(s),jacket coatings, films, fibers, tubes, wire coatings and the like) byconventional melt extruding, injecting or casting means.

The term “thermoplastic” as used herein, refers to polymers that arepliable or moldable above a specific temperature and return to a solidstate upon cooling. These polymers have the property of becoming softwhen they are heated and of becoming rigid again when they are cooled,without undergoing an appreciable chemical change. Such a definition maybe found, for example, in the encyclopedia called “Polymer ScienceDictionary”, Mark S. M. Alger, London School of Polymer Technology,Polytechnic of North London, UK, published by Elsevier Applied Science,1989.

As used herein, the term “elastomer” is intended to designate a trueelastomer or a polymer resin serving as a base constituent for obtaininga true elastomer. True elastomers are defined by the ASTM, SpecialTechnical Bulletin, No. 184 standard as materials capable of beingstretched, at room temperature, to twice their intrinsic length andwhich, once they have been released after holding them under tension for5 minutes, return to within 10% of their initial length in the sametime.

As used herein, the term “active nucleating agent” is intended to denotea compound which acts both as a nucleating agent, as above describedand, at the same time, participates in blowing, by at least partiallydecomposing to yield gaseous components.

As used herein, the terms “substantially halogen-free” or “substantiallynon-halogenated,” and “substantially free of halogens” and similar termsare used interchangeably and describe a composition or an article ofmanufacture that is substantially free of one or more halogens (e.g.fluorine, chlorine, bromine, iodine). Such a composition (or article ofmanufacture) can be a composition (or article of manufacture) in whichthe halogen concentration is less than 10%, less than 5%, less than 2%,or less than 1% by weight of said composition (or article ofmanufacture). The substantially non-halogenated composition is acomposition that is greater than 90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%,98%, 99%, 99.5%, or 99.9% free by weight of a (one or more) halogen. Thecompositions and articles of manufacture described herein that aresubstantially free of halogens may contain undetectable or untraceableamounts of halogens.

As used herein, “foaming level” is the ratio of the volume of cells in acellular structure, e.g. a cellular separator, relative to the totalvolume of the structure.

Foamable Compositions

In one aspect, it has been discovered that talc (or talc derivative) canbe utilized as a chemical foaming agent for foaming the followingpolymers: polyphenylenesulfide (PPS), polyetherimide (PEI), polysulfone(PSU), polypheylsulfone (PPSU), polyethersulfone (PES/PESU),polyetheretherketone (PEEK), polyaryletherketone (PAEK),polyetherketoneketone (PEKK), polyetherketone (PEK), or polyolefins suchas polyethylene (PE), polyproplylene (PP), cyclic olefin copolymer(COC), polycarbonate (PC), polyphenylene ether (PPE), liquid crystalpolymer (LCP), and/or combinations thereof.

In some embodiments, talc (or talc derivative) can be blended with oneor more of these polymers to provide foamable compositions, which canfoam when exposed to an elevated temperature at which talc (or talcderivative) disintegrates to generate gas. In some embodiments, thefoamable composition comprise at least one of the above polymers (hereinalso referred to as engineered resins) at a concentration in a range ofabout 10% to about 80% by weight of the composition. In someembodiments, the polymer can comprise about 20% to about 70%, about 30%to about 60%, or about 40% to about 50%, by weight of the composition.

The concentration of the talc (or talc derivative) blended with one ormore of the above polymers in a foamable composition according to thepresent teachings can typically vary in a range about 1% to about 50% byweight of the composition. By way of example, in some embodiments, theconcentration of talc (or talc derivative) can be in a range of about 2%to about 40% by weight, about 3% to about 30% by weight, about 4% toabout 20% by weight, about 5% to about 10% by weight, about 6% to about8% by weight or about 7.5% by weight of the foamable composition. Insome embodiments, the foamable composition can comprise talc (or talcderivative) at a concentration of about 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%,9%, 10%, 11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19%, or 20% by weightof the foamable composition.

In some embodiments, talc (or talc derivative) is the only foaming agentpresent in a foamable composition according to the present teachings. Inother embodiments, in addition to talc (or talc derivative), thefoamable composition can include other chemical foaming agents. By wayof example, such additional chemical foaming agents can include, withoutlimitation, magnesium carbonate, calcium carbonate, and dolomite. Insome embodiments, the concentration of such additional foaming agents ina foamable composition according to the present teachings can be, e.g.,in a range of about 0.1% to about 20%. In some embodiments, the combinedconcentration of talc (or talc derivative) and one or more additionalfoaming agents can be in range of about 1% to about 50%, e.g., in arange of about 5% to about 40%, about 10% to about 35%, about 20% toabout 30%.

In some embodiments, in a foamable composition according to the presentteachings, talc (or talc derivative) functions as both a foaming agentas well as a nucleating agent. In other words, in such embodiments, talc(or talc derivative) functions as an active nucleating agent.

In some embodiments, a foamable composition according to the presentteachings can further include a nucleating agent. Some examples ofsuitable nucleating agents include, without limitation, boron nitride(BN), zinc oxide, titanium dioxide, calcium carbonate, clay andnano-clays and carbon and nano-carbons.

The foamable compositions described herein are melt processable, at atemperature sufficient to melt at least one polymer constituent of thecomposition and to cause talc (or talc derivative) to disintegrate so asto generate gas for foaming the composition. For example, in someembodiments, a foamable composition according to the present teachingsis melt processable at a temperature of at least about 600° F., at leastabout 610° F., at least about 620° F., at least about 630° F., at leastabout 640° F., at least about 650° F., at least about 660° F., at leastabout 670° F., at least about 680° F., or at least about 690° F.

In some embodiments, a foamable composition according to the presentteachings can be in the form of a plurality of pellets. As discussed inmore detail below, such pellets can be processed, e.g., via extrusion,so as to fabricate a variety of different types of foamed articles,e.g., separators, wire insulation, cable jackets, etc.

Foamed Articles

The foamable compositions according to the present teachings can beutilized to fabricate a plurality of different types of foamed articles.The foamed articles can include foamed separators, insulation forconductors, tape, cable jackets, and other components of communicationcables as described herein.

In some embodiments, the foamed articles comprise polyphenylenesulfide(PPS), polyetherimide (PEI), polysulfone (PSU), polypheylsulfone (PPSU),polyethersulfone (PES/PESU), polyetheretherketone (PEEK),polyaryletherketone (PAEK), polyetherketoneketone (PEKK),polyetherketone (PEK), or polyolefins such as polyethylene (PE),polyproplylene (PP), cyclic olefin copolymer (COC), polycarbonate (PC),polyphenylene ether (PPE), liquid crystal polymer (LCP), and/orcombinations thereof. In some embodiments, the foamed articles aresubstantially free of halogens. Commercially available solid or foamedflame retardant/smoke suppressed engineered resins, PPS, PEI, PSU, PPSU,PES/PESU, PEEK, PAEK, PEKK, PEK, PE, PP or COC all possess gooddielectric properties. In addition, they also exhibit a good resistanceto burning and generally produce less smoke than FEP under burningconditions. A combination of the two different polymers can reduce costswhile minimally sacrificing physio-chemical properties. Additionaladvantages with the PPS, PEI, PSU, PPSU, PES/PESU, PEEK, PAEK, PEKK,PEK, PE, PP or COC are reduction in cost and toxicity effects asmeasured during and after combustion.

In some embodiments, the foamed articles further comprise one or moreadditives. In one aspect, the additive comprises a smoke suppressantadditive. In another aspect, the additive comprises a flame retardantadditive. In another aspect, the additive comprises a smoke suppressantadditive and a flame retardant additive.

For example, additives for the foamed articles described herein includethe molybdate derivatives, such as molyoxide, ammonium octamolybdate(AOM), calcium molybdate and zinc molybdate, metal oxides, such asOngard II, zinc and other oxides, borates, such as zinc borate and metaborate, stannates, such as zinc hydroxyl stannates and zinc stannates,Nitrogen-Phosphorus, phosphorus based esters, such as triaryl, triaklkyl, and ADP, and magnesium hydrates/carbonates, such as magnesiumhydroxide, magnesium carbonate, and antimony trioxide,decachlorodiphenyloxide, and alumina trihydrate. In one aspect, anadditive is a combination of 2, 3, 4, 5, 6, or more additives. Forexample, an additive comprises zinc oxide. In another aspect, anadditive comprises calcium molybdate. In one aspect, an additivecomprises zinc oxide, calcium molybdate, or combinations thereof. Inanother aspect, the at least one additive comprises antimony trioxideand at least one of decachlorodiphenyloxide, chlorinateddioctylphthalate, and chlorinated diisooctylphthalate.

In some embodiments, the foamable compositions and foamed articles cancomprise blends of PEI, PSU, PPSU, PES, PEEK, PAEK, PE, PP or COC aswell as comprise additives that include C₆₀ fullerenes and compoundsthat incorporate the fullerenes and substituted fullerenes includingnanotubes as well as inorganic clays and metal oxides as required forinsulative or semi-conductive properties in addition to the flame andsmoke suppression requirements.

In some embodiments, the foamed articles can have a tensile strengthgreater than about 2000 psi, greater than about 2500 psi, greater thanabout 3000 psi, greater than about 3500 psi, greater than about 4000psi, greater than about 4500 psi, greater than about 5000 psi, greaterthan about 5500 psi, greater than about 6000 psi, greater than about7000 psi, greater than about 8000 psi, greater than about 9000 psi, orgreater than about 10000 psi. Typically, a foamed article according tothe present teachings exhibits a tensile strength in a range of about2000 psi to about 10,000 psi.

In some embodiments, a foamed article according to the present teachingscan exhibit a specific gravity greater than about 0.75, greater thanabout 1, greater than about 1.1, greater than about 1.2, greater thanabout 1.3, greater than about 1.4, greater than about 1.5, greater thanabout 1.6, greater than about 1.7, greater than about 1.8, or greaterthan about 1.9 g/liter. In some embodiments, a foamed article accordingto the present teachings can exhibit a specific gravity in a range ofabout 0.75 to about 1.5 g/liter.

Some examples of foamed articles according to the present teachingsinclude, without limitation, separators, insulation for electricalconductors, tapes, cable jackets, and fiber optic sheathing.

In some embodiments, the foamed articles described herein exhibit afoaming level of about 10% to about 80%, e.g., in a range of about 15%to about 70%, or in a range of about 20% to about 60%, or in a range ofabout 25% to about 50%, or in a range of about 30% to about 40%. In someembodiments, the foaming level is about 10%, about 15%, about 20%, about25%, about 30%, about 35%, about 40%, about 45%, about 50%, about 55%,about 60%, about 65%, about 70%, about 75%, or about 80%.

In some embodiments, the foamed article can comprise foamed cells havinga maximum dimension (e.g., diameter) in a range of about 0.0005 inchesto about 0.003 inches. In some cases, the foamed cells can have anaverage diameter of about 0.0008 inches. The foamed cells can have aclosed cell structure, an open cell structure, or a combination thereof.In some embodiments, a majority of the foamed cells (e.g., greater than50%) have a closed cell structure. For example, greater than 50%,greater than 60%, greater than 70%, greater than 80% or greater than 90%of the foamed cells have a closed cell structure. Another embodimentincludes talc, during blowing or foaming, reacting synergistically withanother composition (e.g., MgCO₃) to form smaller, more uniform cellstructures in the foamed or blown other composition.

Separators

In one aspect, the invention provides separators, e.g., for use intelecommunications cables, that provide shielding of electromagneticradiation. In some embodiments such separators can be formed intopredefined shapes, e.g., by extrusion via a die. For example, a die witha cross-shaped opening can be used to form an elongated separator thathas an elongated cross-shaped form. By way of example, FIGS. 2A and 2Bschematically depict a pre-formed foamed separator 10 according to oneembodiment of the invention that has an elongated cross-shaped form,which extends from a proximal end 20 to a distal end 30. The separator10 provides four elongated channels 40A, 40B, 40C, 40D, in each of whichone or more conductors, e.g., a twisted-pair wire, can be disposed. Inmany embodiments, the separator 10 is particularly effective in loweringthe cross-talk in a frequency range of about 1 MHz to about 40 GHz, orin a range of about 1 MHz to about 10 GHz, or in a range of about 1 MHzto about 2 GHz, or in a range of about 1 MHz to about 1.5 GHz betweenthe conductors disposed in neighboring channels. In other embodiments,the separator 10 is particularly effective in lowering cross-talk in afrequency range of about 500 MHz to about 1 GHz, in a range of about 500MHz to about 10 GHz, in a range of about 1 MHz to about 40 GHz, in arange of about 1 MHz to about 10 GHz, in a range of about 1 MHz to about2 GHz, or in a range of about 1 MHz to about 1.5 GHz. These frequencyranges are particularly useful for separators in cables used for highspeed transmission of information. For example, to transmit informationthrough a cable at a higher bit rate, a higher bandwidth is requiredwhich, in turn, requires transmission of signals at higher frequencies.

Current data cabling performance requirements are defined byANSI-TIA-568-C.2. One performance requirement for communications cablesis known as attenuation to crosstalk ratio, far end (“ACRF”). ACRF is ameasure of how much signal is received at the far end of a given cableas a ratio of the interfering signal induced by adjacent conductor pairsin the cable. Improved reduction of cross talk between conductors in acable can enable data transmission at higher frequencies. For example,cables that incorporate the separators, tapes, and other materialsaccording to embodiments of the invention can reduce cross talk at agiven frequency, raising ACRF and thereby enabling high performancecable properties.

Referring to FIGS. 2A and 2B, separator 10 comprises any ofpolyphenylenesulfide (PPS), polyetherimide (PEI), polysulfone (PSU),polypheylsulfone (PPSU), polyethersulfone (PES/PESU),polyetheretherketone (PEEK), polyaryletherketone (PAEK),polyetherketoneketone (PEKK), polyetherketone (PEK), or polyolefins suchas polyethylene (PE), polyproplylene (PP), cyclic olefin copolymer(COC), polycarbonate (PC), polyphenylene ether (PPE), liquid crystalpolymer (LCP), and/or combinations thereof.

In some embodiments, the polymer can comprise at least about 30%, or atleast about 40%, or at least about 50%, or at least about 60%, or atleast about 70%, or at least about 80%, or at least about 85%, or atleast about 90%, or at least about 95% of the volume of the separator.

Referring back to FIGS. 2A and 2B, in this embodiment separator 10 has afoamed structure. In other words, a plurality of cells (e.g., gas-filledcells) 50 are distributed throughout separator 10 (the size and thedensity of the cells are not necessarily shown to scale in the figures).While in some embodiments, the cells 50 can be distributed substantiallyuniformly throughout the separator 10, in other embodiments, thedistribution of the cells 50 can be non-uniform. In some embodiments,the cells 50 comprise a volume fraction of the separator 10 in range ofabout 10% to about 50%, e.g., in a range of about 15% to about 45%, orin a range of about 20% to about 40%, or in a range of about 20% toabout 40%, or in a range of about 25% to about 35%. In some embodiments,at least a portion of the cells, or in some cases the majority or evenall of the cells, have a closed structure.

The separator 70 shown in FIG. 3A also has a foamed structure. Separator70 further comprises a center channel 71, which is configured forreceiving a fiber optic cable and/or an electrical conductor. In someembodiments, center channel 71 is empty (i.e., it does not receive afiber optic cable and/or an electrical conductor). This configurationcan allow for the dissipation (e.g., by convection) of heat generatedfrom the electrical conductors disposed in the channels defined by theseparator 70. The fiber optic blown tube for fiber and/or electricalconductor channel 71 runs substantially along the center of separator70.

As shown schematically in FIG. 6, in use, a plurality of conductors 331can be disposed in the channels 320A, 320B, 320C, and 320D provided bythe separator 310. The conductors can be, for example, twisted pairs ofwires. The separator 310 minimizes, and preferably eliminates,cross-talk between the conductors 331 disposed in channels 320A, 320B,320C, and 320D. For example, when conductors 331 are used to transmittelecommunications data at rates up to about 100 Gbits/sec, or in arange of about 1 Mbit/sec to about 100 Gbits/sec, or in a range of about1 Mbit/sec to about 40 Gbits/sec., the foamed structure of the separatorcan facilitate electromagnetic shielding of the conductors disposed inneighboring channels from one another. The shielding can in turnminimize, and preferably effectively eliminate, the cross-talk betweenthe neighboring conductors at frequencies corresponding to those emittedby the conductors, e.g., frequencies in a range of about 500 MHz toabout 1 GHz or a frequencies in a range of about 500 MHz to about 10GHz.

Conductors, such as the insulated twisted pairs, for example shown inFIGS. 4 and 5, can be disposed in each channel of separator 110 or 210according to the present teachings. The pairs run the longitudinallength of the separator. While this embodiment depicts one twisted pairper channel, there may be more than one pair per channel. The twistedpairs are insulated with a suitable polymer, copolymer, or dual extrudedfoamed insulation with solid skin surface. The conductors are thosenormally used for optical or conventional data transmission. The twistedpairs may be banded such that the insulation of each conductor isphysically or chemically bound in an adhesive fashion, or an externalfilm could be wrapped around each conductor pair to provide the sameeffect. Although some embodiments utilize twisted pairs, one couldutilize various types of insulated conductors within the separatorchannels or cavities.

While the separators 110 and 210 have a cross-shaped cross-sectionalprofile, in other embodiments the separator can have other shapes. Otherexemplary shapes that can be used for separators according to thepresent teachings are disclosed in US Publication No. 2010/0206609,filed Apr. 6, 2010, entitled “High Performance Support-Separators forCommunications Cables Providing Shielding for Minimizing AlienCrosstalk,” US Publication No. 2007/0151745, filed Mar. 2, 2007,entitled “High Performance Support-Separators for CommunicationsCables,” US Publication No. 2008/0066947, filed Jul. 16, 2004, entitled“Support Separators for Communications Cable,” and U.S. Pat. No.7,098,405, filed May 1, 2002, entitled “High PerformanceSupport-Separator for Communications Cables,” the teachings of which areeach incorporated herein by reference in their entirety.

For example, a separator can have configurations shown in FIGS. 15, 16,17, 18, and 19. As shown and described herein, a separator can be apolymeric preformed elongate support element. The separator extends froma proximal end to a distal end. The separator also defines a pluralityof channels, e.g., 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16,17, 18, 19, 20 or more channels. The channels are each adapted forreceiving, for example, an electrical (e.g., copper) conductor, anoptical fiber cable, or a combination thereof. In some aspects, theseparator may also define a center channel (e.g., see FIGS. 3A-3B),adapted to receive, for example, a copper conductor, an optical fibercable, or a combination thereof. It will be readily apparently to one ofordinary skill in the art that a number of configurations are possiblefor riser and plenum applications. In any of these configurations, theseparator can be formed from a (one or more) substantiallynon-halogenated polymer.

Referring back to FIGS. 2A and 2B, in some embodiments, the separator 10is substantially halogen-free. For example, in some embodiments, theseparator 10 can be formed of one or more substantially non-halogenatedpolymer. In some embodiments, such a halogen-free separator can beformed by using only one or more of the engineered resins disclosedherein. In some embodiments, the separator 10 can further includenon-halogen additives, such as those disclosed herein. Such ahalogen-free separator according to the present teachings can be used incables, e.g., telecommunications cable, that can satisfy the moststringent standards, such as the North American Standard for Plenum(CMP) U.L. 910, North American Standard for Riser (CMR) U.L. 1666Vertical and the European Standard Class B1_(ca), B2_(ca), and C_(ca).

The separators described herein can be used in a variety of cables,including shielded and unshielded cables. A shielded cable comprises ametal braid, metal tape, or both that surrounds the separator 10 toprovide shielding of alien cross-talk. In some cases, in use, the metalbraid, metal tape, or both can be grounded. The metal braid, metal tape,or both is in turn surrounded by a jacket, which can be formed of apolymeric material. In some embodiments, the jacket is formed of apolymer, such as polyphenylenesulfide (PPS), polyetherimide (PEI),polysulfone (PSU), polypheylsulfone (PPSU), polyethersulfone (PES/PESU),polyetheretherketone (PEEK), polyaryletherketone (PAEK),polyetherketoneketone (PEKK), polyetherketone (PEK), or polyolefins suchas polyethylene (PE), polyproplylene (PP), cyclic olefin copolymer(COC), polycarbonate (PC), polyphenylene ether (PPE), liquid crystalpolymer (LCP), and/or combinations thereof.

In some embodiments, the foamed articles described herein such as theseparators, exhibit a foaming level of about 10% to about 80%, e.g., ina range of about 15% to about 70%, or in a range of about 20% to about60%, or in a range of about 25% to about 50%, or in a range of about 30%to about 40%. In some embodiments, the foaming level is about 10%, about15%, about 20%, about 25%, about 30%, about 35%, about 40%, about 45%,about 50%, about 55%, about 60%, about 65%, about 70%, about 75%, orabout 80%.

In some embodiments, the separator 10 can comprise an additive, such asa smoke suppressant additive. In another aspect, the additive comprisesa flame retardant additive. Some examples of suitable additives includemolybdate derivatives, such as molyoxide, ammonium octamolybdate (AOM),calcium molybdate and zinc molybdate, metal oxides, such as Ongard II,zinc and other oxides, borates, such as zinc borate and meta borate,stannates, such as zinc hydroxyl stannates and zinc stannates,Nitrogen-Phosphorus, phosphorus based esters, such as triaryl, triaklkyl, and ADP, and magnesium hydrates/carbonates, such as magnesiumhydroxide, magnesium carbonate, and antimony trioxide,decachlorodiphenyloxide, and alumina trihydrate. In some embodiments, anadditive is a combination of 2, 3, 4, 5, 6, or more additives. Forexample, an additive can comprise zinc oxide, calcium molybdate, or acombination of zinc oxide and calcium molybdate.

In some embodiments, the separators described herein in accordance withthe present teachings can include rifled slot members or “saw-blade”like members. For example, FIG. 25 is a cross-sectional view ofseparator 103, which provides a plurality of channels 104 and includesrifled slots (members) or “saw-blade” like members 105. The use ofinterior slotted rifled slot sections allows for improved heatdissipation (i.e., cooling of the cable) based on the overall depth andnumber of slots of the rifled section. This allows for more air todissipate heat (e.g., via convection) generated by the electricalconductors or twisted pairs. Separator 103 with rifled slots can besolid or foamed and can be formed of one or more polymeric materials(e.g., one or more engineered resins).

In some embodiments, rifled slot separators disclosed in published U.S.patent application Ser. No. 13/183,733, filed Jul. 15, 2011, thecontents of which are incorporated by reference, can be foamed inaccordance with the present teachings, e.g., by using one or moreengineered resins and employed in PoE cables.

For example, shown in FIG. 26, separator 203 is asymmetrical and cancomprise one or more polymeric materials (i.e., engineered resins) inaccordance with the present teachings. The vertical and horizontalsections along an axis can have varying widths. The left side horizontalmember 215 is narrower in width than that of the right side horizontalmember 216. Similarly, the vertical member 217 extending in an upwarddirection is narrower in width than that of the other vertical member218. Separator 203 can include rifled slots (members) or “saw-blade”like members. As described herein, this configuration can allow for thedissipation of heat (e.g., by convection) generated from the electricalconductors.

In another embodiment, FIG. 27 illustrates separator 1800 includingrifled slots (members) and is symmetrically balanced. Separator 1800 canoptionally be formed using a solid or foamed polymeric material (e.g.,substantially free of halogen) as described herein. The rifled separatorcan also have four “tipped” ends that have key-like features 1810. Therifled cross separator provides channels for conductors or conductorpairs 1825 (i.e., twisted pairs) that can be insulated. Each conductoror conductor pair can include an outer insulation material 1830 and anelectrically conducting portion of the conductor 1835. A hollow centerchannel in the center 1820 can optionally aid for the purpose of heatdissipation and heat reduction of the cable.

FIG. 28A depicts a cross-section of an anvil-shaped separator. Theanvil-shaped separator can include four channels (300, 302, 304, and306) that are configured to receive electrical conductors (e.g., twistedpairs) and/or fiber optic cables. The channel centers are about 90degrees apart relative to the center of the separator. As illustrated inFIG. 28A, in each channel is one set of twisted pairs (310, 312, 314,and 316). This embodiment also includes a cavity in the center (e.g.,center channel) 320 of the anvil-shaped separator for an electricalconductor, fiber optic cable, or air. The exploded view of FIG. 28A alsoindicates the use of an interior slotted rifled section or sections 332that allows for improved heat dissipation (i.e., cooling of the cable)based on overall depth and number of slots of the rifled section andimproving electrical characteristics as described above (allowing formore air around each insulated conductor or pair). As shown in the otherexploded view (334), the individual conductor may compress against asolid or foamed slotted rifled surface (e.g., a polymeric engineeredresin) to ensure the semi-permanently fixed position.

FIG. 28B depicts an embodiment of an anvil-shaped separator which hasend sections 810, 812, 814 and 816 to reduce weight and allow for thedissipation of heat (e.g., by convection) generated from the electricalconductors resulting in enlarged channels for electrical conductorsand/or fiber optic cables. This separator also has rifled slots withineach channel and an optional asymmetric conductor pair offset due to theskewed elongated axis.

The separators shown, for example, in FIGS. 25-28, can be substantiallyfree of halogens (e.g., an engineered resin) in accordance with thepresent teachings. It will be readily apparent that any of theseparators, such as, for example, those illustrated in FIGS. 15-19C, caninclude rifled slots or “saw-blade” like members. The separatorsillustrated in FIGS. 25-28 can be foamed or solid. The rifled orribbed-like structures can allow for and aid in cooling of the cable.The rifled structures create space (i.e., air gaps) within the cable(e.g., between a jacket and the separator, between the twisted pairs andthe separator, etc.). Air inside can cool the cable through convection,allowing air to travel along the cable, mitigating heat rise.

Insulation for Conductors

In one aspect, the present invention provides insulation for metalconductors. In some embodiments, such insulation can have a multi-layerstructure formed, e.g., of different polymeric materials. For example,the insulation can include a bi-layer structure in which the inner layer(i.e., the layer in direct contact with the conductor) is a foamedpolymeric layer, and the outer layer is either a foamed or a solidpolymeric layer. In some embodiments, one or both layers include flameretardant and/or smoke suppressant additives. In some embodiments, abi-layer structure can be extruded in tandem or co-extruded.

By way of example, FIG. 6 schematically depicts an insulated twistedpair of electrical conductors 330 according to an embodiment of thepresent teachings, which includes a centrally disposed elongatedelectrical conductor 331 and an insulation 340 that surrounds theelectrical conductor. In some embodiments, the electrical conductor 331can comprise copper or silver, though other metals can also be employed.For example, the electrical conductor 331 can be formed of any of 16,18, 20, 22, or 24 AWG copper.

In some embodiments, the insulation 340 includes an inner layer 341 andan outer layer 342. The inner layer 341 can completely or partiallysurround the electrical conductor 331 and the outer layer 342 cancompletely or partially surrounding the inner layer 341.

In some embodiments, the thickness of the insulation 340 can be, e.g.,in a range of about 0.005 to about 0.009 inches. By way of example, theinner layer 341 can have a thickness in a range of about 3.5 to about8.0 mils and the outer layer 342 can have a thickness in a range ofabout 3.5 to about 8.0 mils.

In this embodiment, the inner layer 341, which is in contact with andsurrounds the electrical conductor 331, comprises a foamed or a solidpolyolefin. By way of example, the inner layer 341 can comprise a foamedpolyolefin, such as a foamed polyethylene, a foamed polypropylene, or afoamed cyclic olefin copolymer. Further, in some embodiments, the innerlayer can comprise solid or foamed polyphenylenesulfide (PPS),polyetherimide (PEI), polysulfone (PSU), polypheylsulfone (PPSU),polyethersulfone (PES/PESU), polyetheretherketone (PEEK),polyaryletherketone (PAEK), polyetherketoneketone (PEKK),polyetherketone (PEK), or polyolefins such as polyethylene (PE),polyproplylene (PP), cyclic olefin copolymer (COC), polycarbonate (PC),polyphenylene ether (PPE), liquid crystal polymer (LCP), and/orcombinations thereof. In some embodiments, the inner layer can comprisea silicone polymer.

In some embodiments, a smoke and/or flame retardant additive can beadded to the inner layer. In some embodiments, such additive caninclude, without limitation, magnesium complexes, molybdate complexes,phosphate complexes, alumina trihydrate (ATH), zinc borate, zinc oxideor talc (or talc derivative) or a combination of two or more of suchadditives. By way of example, in some embodiments, particulates (e.g.,particles, such as nanosized particles) of zinc oxide (ZnO), or calciummolybdate (or other smoke and/or fire retardant) can be added to theinner layer. In some embodiments, a combination of zinc oxide and ATH isadded to the inner layer for both flame retardancy and smokesuppression. In some embodiment, the molybdate complexes added to theinner layer can include, without limitation, molybdenum oxide, calciummolybdate, zinc molybdate, ammonium octamolybdate. In some embodiment,the additive added to the inner layer can be a phosphate complex, suchas ammonium polyphosphate, melamine phosphate, or PNS phosphate.

By way of example, in some embodiments, the inner layer is formed of afoamed polyolefin and the outer layer is formed of solid PEEK.

In some embodiments, both the inner and the outer layer aresubstantially halogen-free so that to provide a halogen-free insulation.As discussed in more detail below, such halogen free insulation can beused for electrically insulating conductors employed in a halogen-freecable. Again, as discussed in more detail below, such a halogen-freecable can meet the most stringent tests for flame retardancy and smokesuppression, such as the North American Standard for Plenum (CMP) U.L.910, North American Standard for Riser (CMR) U.L. 1666 Vertical and theEuropean Standard Class B1_(ca), B2_(ca), and C_(ca).

Referring to FIG. 7, an insulation 410 according to the presentteachings, surrounds a conductor 420 (which is a copper wire in thisembodiment, but can be any other suitable conductor). The insulation 410includes a plurality of cavities 430A, 430B, 430C, 430D, and 430E(herein referred to collectively as cavities 430). In some embodiments,these cavities are filled with air, though other gases can also beemployed. The insulation 410, which can be a solid or a foamedinsulation, comprises any of PEI, PSU, PPSU, PEEK, and PEK. In someembodiments, flame retardant and/or smoke suppressant additives, such asthose listed above, can be added to the insulation 410.

FIG. 8 schematically depicts an insulation 510 according to anotherembodiment, which surrounds a conductor 520, such as an elongate copperconductor. The insulation 510 includes an inner layer 540 and an outerlayer 550. The inner layer can be a solid or foamed polymeric layer,such as the inner layer 540 discussed in connection with FIG. 4. Similarto the previous embodiment, the insulation 510 includes a plurality ofcavities 530, which are filled with air or other gases. In someembodiments, the inner layer 540 can comprise a solid or foamedpolyolefin. One or more flame retardant and/or smoke suppressantadditives can be added to the inner layer 540, such as the additivesdiscussed in connection with the embodiment of FIG. 4. The insulation510, which can be a solid or a foamed insulation, comprises any of PEI,PSU, PPSU, PEEK, and PEK. In some embodiments, flame retardant and/orsmoke suppressant additives, such as those listed above, can be added tothe insulation 510.

Tapes

In some embodiments, a flexible tape (e.g., a non-woven tape) can befabricated using any of polyphenylenesulfide (PPS), polyetherimide(PEI), polysulfone (PSU), polypheylsulfone (PPSU), polyethersulfone(PES/PESU), polyetheretherketone (PEEK), polyaryletherketone (PAEK),polyetherketoneketone (PEKK), polyetherketone (PEK), or polyolefins suchas polyethylene (PE), polyproplylene (PP), cyclic olefin copolymer(COC), polycarbonate (PC), polyphenylene ether (PPE), liquid crystalpolymer (LCP), and/or combinations thereof. By way of example, FIG. 10schematically depicts a non-woven tape 120, which comprises a pluralityof fibers formed of any of polyolefins, PSU, PPSU, PEEK, PEK, or acombination thereof. In some embodiments, the tape 120 is sufficientlyflexible to be configured into a desired shape (e.g., for wrappingaround one or more conductors). By way of example, the exemplary tapecan be utilized as a flexible separator to electrically isolate (or atleast partially electrically isolate) one or more conductors (e.g., atwisted pair) from other conductors.

In some embodiments, the tape 120 is substantially halogen-free.

The above tape 120 having a plurality of electrically conductiveinclusions 130 can be manufactured in a variety of ways. By way ofexample, with reference to flow chart of FIG. 21 in one exemplary methodof manufacturing the tape, a plurality of polymer pellets, e.g., pelletsformed using any of PSU, PPSU, PEEK, PEK can be melted (step 1) and themolten pellets can be extruded to form the tape (step 2). The tape canbe formed, e.g., by methods discussed in some of the examples providedbelow.

In some embodiments, the non-woven tape can comprise any of theengineered resin described herein. The tape can be wrapped around theseparator to enclose the twisted pairs or optical fiber bundles. In someembodiments, a layered metal can be disposed on one or both surfaces ofthe tape.

Referring to FIG. 20, tape 10010 can be wrapped around twisted pairs10030, 10031, 10032 and 10033 (e.g., pairs of copper conductors). Eachtwisted pair can also be wrapped in a tape 10020. In some embodiments,one or more (e.g., 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12 or more)twisted pairs are wrapped together in a tape.

Cable Jackets

In another aspect, the invention provides a jacket for a cable, e.g., acommunications cable. As discussed in more detail below, the jacket cancomprise one or more of polyphenylenesulfide (PPS), polyetherimide(PEI), polysulfone (PSU), polypheylsulfone (PPSU), polyethersulfone(PES/PESU), polyetheretherketone (PEEK), polyaryletherketone (PAEK),polyetherketoneketone (PEKK), polyetherketone (PEK), or polyolefins suchas polyethylene (PE), polyproplylene (PP), cyclic olefin copolymer(COC), polycarbonate (PC), polyphenylene ether (PPE), liquid crystalpolymer (LCP), and/or combinations thereof. While in some embodiments, acable jacket according to the present teachings can have a solidstructure, in other embodiments it can have a foamed structure.

By way of example, FIG. 4 schematically depicts a cable jacket 150according to one embodiment of the invention that has an elongatetubular shape and extends from a proximal end to a distal end. Theelongate tubular shape of the cable jacket forms a shell, e.g., apolymeric shell, having an interior lumen, which can be employed tohouse cable components such as one or more conductors, separators,optical fibers, etc.

In some embodiments, a cable jacket according to the present teachingsis substantially free of a halogen. By way of example, the cable jacketcan be formed as a solid or foamed structure comprising one or more of apolyolefin, PPS, PEI, PSU, PPSU, PES/PESU, PEEK, PAEK, PEKK, or PEK or acombination thereof and be substantially free of any halogen.

In many embodiments, the cable jacket 150 can be particularly effectivein lowering alien cross-talk. For example, the cable jacket 150 can beeffective at reducing alien cross-talk with a frequency range up toabout 30 GHz. For example, the cable jacket can be effective in reducingor mitigating the alien cross-talk beyond the industry-specified sweptfrequency limits. Examples of these industry-specified standards areTIA-568-C.2. and ISO 11801. If a product mitigates alien cross-talk, itcan also have the same effect on ingress noise. For example, in a cabletray where many different types of cables are routed throughout thebuilding, it is normal to have power cable and data cables next to eachother. Transient power spikes regularly pass down power cables. Thesespikes can interrupt data transmission for brief moments. In anunshielded twisted pair cable, the balanced pairs are the firstmitigating feature, the jacket is the second.

The above cable jackets can be manufactured in a variety of ways. In oneexemplary method of manufacturing the cable jackets, the foamablecomposition can be extruded to form the jacket.

Communication Cables

In another aspect, the invention provides cables, e.g., communicationscables, which can comprise one or more of the articles described herein.For example, the communication cables can comprise any one of theseparators, conductors having insulation according to the presentteachings, tapes, cable jackets and/or the nonwoven fabrics describedherein to provide the properties described herein, such as, for example,electromagnetic shielding of the conductors disposed in the cable andflame and smoke retardant properties.

By way of example, FIG. 4 schematically depicts a communications cable100 accordingly to one embodiment. The cable 100 includes separator 110in accordance with the present teachings, e.g., similar to separator 10discussed above, which provides four channels 160A, 160B, 160C and 160Dfor receiving transmission media. In this embodiment, the separator 110has a foamed structure and comprises any of polyphenylenesulfide (PPS),polyetherimide (PEI), polysulfone (PSU), polypheylsulfone (PPSU),polyethersulfone (PES/PESU), polyetheretherketone (PEEK),polyaryletherketone (PAEK), polyetherketoneketone (PEKK),polyetherketone (PEK), or polyolefins such as polyethylene (PE),polyproplylene (PP), cyclic olefin copolymer (COC), polycarbonate (PC),polyphenylene ether (PPE), liquid crystal polymer (LCP), and/orcombinations thereof. Further, in this embodiment of the communicationscable 100, the separator 110 is substantially halogen free.

In this embodiment, transmission media 131 disposed in each channelcomprises a twisted pair of conductors 130. Each conductor 131 includesan insulation 140 comprising an inner layer 141 and outer layer 142according to the present teachings. In this embodiment, the insulation140 is substantially halogen free.

In some embodiments, the communications cable 100 further comprises atape (not shown) that completely, or partially, surrounds each of theinsulated twisted pair of electrical conductors 130.

The communications cable 100 further comprises a cable jacket 150 formedaccording to the present teachings. For example, in this embodiment,jacket 150 comprises any of polyphenylenesulfide (PPS), polyetherimide(PEI), polysulfone (PSU), polypheylsulfone (PPSU), polyethersulfone(PES/PESU), polyetheretherketone (PEEK), polyaryletherketone (PAEK),polyetherketoneketone (PEKK), polyetherketone (PEK), or polyolefins suchas polyethylene (PE), polyproplylene (PP), cyclic olefin copolymer(COC), polycarbonate (PC), polyphenylene ether (PPE), liquid crystalpolymer (LCP), and/or combinations thereof. In this embodiment, jacket150 has a solid structure and comprises a tensile strength of about2,000 psi to about 10,000 psi. Further, in this embodiment, the jacket150 is substantially halogen free. In other embodiments, the jacket 150can have a foamed structure, and can be substantially free of halogens.

Thus, in this embodiment, the communications cable 100 is substantiallyhalogen free.

Communications cable 100 can also be configured as a Power over Ethernet(PoE) cable, in accordance with the present teachings. In someembodiments, at least one of the twisted pairs can transmit electricalpower along with or without electrical data, e.g., power in the range ofabout 1 watt to about 25 watts.

Another exemplary embodiment of a communications cable comprising aseparator is depicted in FIG. 5. Communication cable 200 comprisesseparator 210 that provides channels 260A, 260B, 260C and 260D forreceiving transmission media. In this embodiment, the separator 210 hasa foamed structure and comprises any of polyphenylenesulfide (PPS),polyetherimide (PEI), polysulfone (PSU), polypheylsulfone (PPSU),polyethersulfone (PES/PESU), polyetheretherketone (PEEK),polyaryletherketone (PAEK), polyetherketoneketone (PEKK),polyetherketone (PEK), or polyolefins such as polyethylene (PE),polyproplylene (PP), cyclic olefin copolymer (COC), polycarbonate (PC),polyphenylene ether (PPE), liquid crystal polymer (LCP), and/orcombinations thereof. Separator 210 has center channel 270 configuredfor receiving a fiber optic cable, twisted pair, coax, or strengthmember. The center channel 270 includes a cavity that runs along thelength of the separator 210 in which, for example, a fiber optic cablemay be inserted. Further, in this embodiment of the communications cable200, the separator 210 is substantially halogen free.

In some embodiments, center channel 270 can be empty (i.e., it does notreceive a fiber optic cable). This configuration can allow for thedissipation (e.g., by convection) of heat generated from the electricalconductors from the channels defined by the separator 210.

In this embodiment, transmission media 231 disposed in each channelcomprises a twisted pair of conductors 230. Each conductor 231 includesan insulation 240 comprising an inner layer 241 and outer layer 242according to the present teachings. In this embodiment, the insulation240 is substantially halogen free.

In this embodiment, the communications cable 200 further comprises atape 220 that completely, or partially, surrounds each of the insulatedtwisted pair of electrical conductors 230.

The communications cable 200 further comprises a cable jacket 250 formedaccording to the present teachings. For example, in this embodiment,jacket 250 comprises any of polyphenylenesulfide (PPS), polyetherimide(PEI), polysulfone (PSU), polypheylsulfone (PPSU), polyethersulfone(PES/PESU), polyetheretherketone (PEEK), polyaryletherketone (PAEK),polyetherketoneketone (PEKK), polyetherketone (PEK), or polyolefins suchas polyethylene (PE), polyproplylene (PP), cyclic olefin copolymer(COC), polycarbonate (PC), polyphenylene ether (PPE), liquid crystalpolymer (LCP), and/or combinations thereof. Jacket 250 has a solidstructure and comprises a tensile strength of about 2,000 psi to about10,000 psi. Further, in this embodiment, the jacket 250 is substantiallyhalogen free.

Thus, in this embodiment, the communications cable 200 in FIG. 5 issubstantially halogen free.

By way of further illustration, FIG. 9 depicts a twisted pair ofconductors disposed in a channel 600 provided by a separator accordingto the present teachings. Each conductor comprises an electricallyconductive core 620, e.g., copper core, surrounded by an inner layer 640and outer layer 650. In this embodiment, the inner layer 640 comprisesan engineered resin and can have a thickness in a range of approximately1 to about 7 mm. A foamed or solid outer layer 630 comprises anengineered resin such as, for example, PEI, PSU, PPSU, PEEK, and/or PEK.Alternatively, the outer layer 650 can comprise polyethylene,polypropylene or cyclic olefin. The outer layer 610 can have a thicknessin a range of approximately 3 mm to about 35 mm.

In other embodiments, the separator comprises a center channel or centerregion that extends along the longitudinal length of the cable. Thecenter channel or center region can be configured for a fiber opticcable, twisted pair, coax, or strength member. The center region caninclude a cavity that runs the length of the separator in which, forexample, a fiber optic cable may be inserted.

In some embodiments, a strength member may be added to the cable. Thestrength member can be located in the central region of the separatorand can run the longitudinal length of the separator. The strengthmember can be formed, e.g., of a solid polyethylene or other suitableplastic, textile (nylon, aramid, etc.), fiberglass flexible or rigid(FGE rod), or metallic material.

Cable 200, as shown in FIG. 29 is an example of a high performance cable(e.g., a PoE cable) having electrical conductors that carry data,electrical power, or a combination thereof. The cable has an optionalouter jacket 210 that can be solid or foamed, comprising a substantiallyhalogen free polymeric material (e.g., an engineered resin).Additionally, the jacket can be smooth/ribbed 210. Any of the separatorsdescribed herein, e.g., separators illustrated in FIGS. 25-28, can besurrounded by jacket 210. For example, having a separator depicted inFIG. 28A or 28B, having channels can allow for the dissipation of heatfrom one or more electrical conductors (e.g., through convention).

Tight and Loose Buffer Cables

Tight buffer construction cables offer an enhanced design for commercialcommunication applications that require a high level of performance foroptical fibers. Due to the diverse applications, there is a need forthese cables to exhibit excellent fiber protection, flexibility, ease ofhandling and termination, and meet stringent flame-retardant standards.By way of illustration, FIG. 11 depicts a buffer cable 1000 comprising abuffer 1010, which can have in some embodiments an outer diameterranging from about 250 microns to about 900 microns and inner diameterranging from about 7 microns to about 250 microns. The buffer 1010encloses fiber optic and cladding 1100. The buffer 1010 can comprise oneor more of the polymers discussed herein. For example, in thisembodiment, the buffer 1010 can comprise any of PPS, PEI, PSU, PPSU,PES/PESU, PEEK, PAEK, PEKK, or PEK, or a combination thereof and besubstantially free of any halogen. Further, in some embodiments, thebuffer 1010 can have a foamed structure, e.g., a foamed structureexhibiting a foaming level in a range of about 10% to about 70%, e.g.,in a range of about 20% to about 60%. Alternatively, in someembodiments, the buffer 1010 can have a solid structure.

FIG. 12 schematically demonstrates a plurality of buffers 2010, similarto the buffer 1010, that are surrounded by a jacket 2200. In thisembodiment, each of the buffers 2010 can comprise any of PPS, PEI, PSU,PPSU, PES/PESU, PEEK, PAEK, PEKK, or PEK, or a combination thereof andbe substantially free of any halogen. In addition, the jacket 2200 cancomprise PPS, PEI, PSU, PPSU, PES/PESU, PEEK, PAEK, PEKK, or PEK, or acombination thereof and be substantially free of any halogen. While insome embodiments the jacket 2200 can be in the form of a solidstructure, in other embodiments the jacket 2200 can have a foamedstructure. Further, the jacket 2200 can include flame and/or smokeretardant additives.

Loose buffer construction cables may be buried underground or installedwithin the ducts of a building. Thus, they must provide superior fiberprotection and withstand the adverse effects of the harshestenvironments. As a result, they are subject to various standards andrequirements. In one aspect, FIG. 13 provides blown tubing 3010 forfiber optics that includes a multi-layered structure, which can in manyembodiments facilitate compliance with various standards andrequirements for protection of optical fibers enclosed by the tubing3010. In some embodiments, such insulation can have a multi-layerstructure formed, e.g., of different polymeric materials. For example,the insulation can include a bi-layer structure in which the inner layer3011 is a foamed polymeric layer, and the outer layer 3012 is either afoamed or a solid polymeric layer. For example, the inner layer cancomprise polyolefin and the outer layer can comprise any of PPS, PEI,PSU, PPSU, PES/PESU, PEEK, PAEK, PEKK, or PEK, or a combination thereof.In some embodiments, one or both layers include flame retardant and/orsmoke suppressant additives, such as the additives discussed above. Thisbi-layer structure is extruded, either in tandem or via co-extrusion. Insome embodiments, insulation 3010 can be substantially free of anyhalogen.

FIG. 14 schematically demonstrates a plurality of blown tubes 4010 thatare wrapped in tape 4100 with a jacket 4200 surrounding the tape 4100.The blown tubes 4010 can be formed as discussed above. Similarly, insome embodiments, the tape 4100 can be fabricated in accordance with thepresent teachings. In this embodiment, this jacket 4200 can comprisePPS, PEI, PSU, PPSU, PES/PESU, PEEK, PAEK, PEKK, PEK, or a combinationthereof and be substantially free of any halogen. In some embodiments,the jack 4200 can be formed as a solid structure, and in otherembodiments, it can be formed as a foamed structure, e.g., with afoaming level in a range of about 10% to about 70%. Further, the jacketcan include one or more flame and/or smoke retardant additives, such asthose discussed above.

Power Over Ethernet (PoE)

As the demand for Wi-Fi access points, network security cameras,building access controls (door locks/digital signs, etc.) and lightemitting diodes (LED) grows dramatically, the need for cables that cansupport both copper wires and optical fibers increases. In someembodiments, the present teachings provide hybrid fiber/copper cablesthat utilize a 4 or 8-pair copper design with an embedded fiber opticduplex or two-fiber design as depicted in FIGS. 15, 16 and 17.Currently, for both Riser and Plenum Hybrid Cable POE Design, ahalogen-free solution does not exist; nor is there a solution to theneed for higher temperature rated design from the 60° C. rating to thegreater than 125° C. rating that this invention can offer with foamed orsolid engineered polymers.

Referring to FIG. 15, a Power Over Ethernet cable 5000 includes 4 pairsof copper cables 5010, 5011, 5012 and 5013, with each pair disposed inone of four longitudinal channels provided by a crossweb separator 5100,and two optical fiber channels 5200 and 5201, which are disposed withina central channel of the crossweb 5100. Although cable 5000 is shownhaving two optical fiber cables 5200 and 5201 in center channel, in someaspects the center channel can be empty, i.e., not have optical fibercables 5200 and 5201. Such a configuration can allow for the rapiddissipation of heat generated from, e.g., twisted pairs 5010, 5011,5012, and/or 5013. The copper cables can have insulation according tothe present teachings, which can be in some cases substantially free ofhalogens. The insulation can comprise a solid or foamed non-halogenpolymer. The insulation can be a composite insulation, for example, asshown in FIG. 9, or the slotted or airspace design shown in FIGS. 7 and8.

The crossweb 5100 can also be formed according to the present teachings(see, e.g., the discussion of separators above) and can be in someembodiments substantially free of halogens. In some embodiments, thecrossweb 5100 can have a foamed structure.

Each of the optical fiber channels includes a blown tube (5200′ and5201′), which encloses an optical fiber. The blown tubes can be formedin accordance with the teachings provided herein (see, e.g., FIGS. 11,12, and 13 and the associated discussion). In some embodiments, theblown tubes can be substantially free of halogens. A jacket 5500surrounds the blown tubes. The jacket 5500 can be formed in accordancewith the present teachings, and can be in some cases substantially freeof halogens. In some embodiments, a yarn 5600 (e.g., Aramid yarn) fillsthe space between the blown tubes. The yarn 5600 can comprise one ormore of the engineered resins disclosed herein. For example, the Aramidyarn or yarns can comprise any of polyphenylenesulfide (PPS),polyetherimide (PEI), polysulfone (PSU), polypheylsulfone (PPSU),polyethersulfone (PES/PESU), polyetheretherketone (PEEK),polyaryletherketone (PAEK), polyetherketoneketone (PEKK),polyetherketone (PEK), or polyolefins such as polyethylene (PE),polyproplylene (PP), cyclic olefin copolymer (COC), polycarbonate (PC),polyphenylene ether (PPE), liquid crystal polymer (LCP), and/orcombinations thereof.

Further, the cable 5000 includes an outer jacket 5400, which can also beformed according to the present teachings and can be in some casessubstantially free of any halogens (see, e.g., FIG. 4 and the associateddiscussion). By way of example, the cable 5000 can be used in plenum andriser applications. Comprising one or more non-halogen polymersdescribed herein.

FIG. 16 schematically depicts a Power Over Ethernet cable 6000 accordingto another embodiment. The cable 6000 includes a separator 6001 thatprovides 8 channels in each of which a pair of copper wires (6002, 6003,6004, 6005, 6006, 6007, and 6008) is disposed. The insulation of thecopper wires as well as the separator are formed according to thepresent teachings, and can be in some embodiments substantially fee ofhalogens. Similar to the previous embodiment, the cable 6000 includestwo buffered optical fibers 6200 and 6201, which are enclosed within abuffer tube 6400 that is disposed within a hollow central channel of theseparator 6100. The buffered fibers 6200 and 6201 as well as the buffertube 6400 can be formed in accordance with the present teachings and insome cases can be substantially free of halogens. In some embodiments,cable 6000 does not include buffered fibers 6200 and 6201 in a centerchannel, leaving it unoccupied for improved heat dissipation (e.g.,through convection) of the twisted pairs (of copper wires). The cable6000 further includes an outer jacket 6300, which can also be formed inaccordance with the present teachings and can be in some casessubstantially free of halogens. By way of example, the cable 6000 can beused for plenum and riser applications.

By way of further illustration, FIG. 17A depicts another embodiment of aPower Over Ethernet cable 7000 according to the present teachings, whichincludes a separator 7001 that provides five longitudinal channels. Infour of these channels, 4 pairs of copper wires (e.g., twisted pairs)(7002, 7003, 7004, and 7005) are disposed. In the remaining channel, twonested buffered optical fibers 7100 and 7101 are disposed. The opticalfibers are similar to those discussed above in connection with theprevious embodiments. One or both of the electrical conductors of thetwisted pairs 7002, 7003, 7004, and 7005 can be configured to carryelectrical data, power, or combinations thereof. A jacket 7200 surroundsthe internal components of the cable. In this embodiment, the insulationof the copper wires, the separator, the fiber optic channels and thejacket are formed in accordance with the present teachings, and arepreferably substantially free of halogens. Further, in this embodiment,the separator has a flap top design that can mitigate alien crosstalk.

While the separator 7001 shown in FIG. 17A is formed as a solidpolymeric structure, in other embodiments it can be foamed. For example,referring to FIG. 17B, PoE cable 7000 includes separator 7001 that isfoamed, having substantially uniformly sized cells 7400. Separator 7001provides five longitudinal channels 7300. In four of these channels, 4twisted pairs (e.g., pairs of copper conductors) 7002, 7003, 7004, and7005 are disposed. In the remaining channel, two nested buffered opticalfibers 7100 and 7101 are disposed. The optical fibers are similar tothose discussed above in connection with the previous embodiments. Oneor both of the copper conductors of the twisted pairs 7002, 7003, 7004,and 7005 can be configured to carry electrical data, power, orcombinations thereof. A jacket 7200 surrounds the internal components ofthe cable. In this embodiment, the insulation of the copper wires, theseparator 7001, the fiber optic channels and the jacket are formed inaccordance with the present teachings, and are preferably substantiallyfree of halogens. Further, in this embodiment, the separator has a flaptop design that can mitigate alien crosstalk. The foaming level of theseparator 7001 can be, for example, in a range of about 20% to about40%, such as about 30%. Further the cells 7400, which can be filled withair, can have a size (i.e., a maximum dimension) in a range of about0.0005 inches to about 0.003 inches. In some cases, the foamed cells7400 can have an average diameter of about 0.0008 inches. Further, insome embodiments, at least about 50%, or at least about 60%, or at leastabout 70%, or at least about 80% of the cells 7400 have a closedstructure.

While the jacket 7200 shown in FIG. 17B is formed as a solid polymericstructure, in other embodiments, it can be foamed. For example,referring to FIG. 17C, PoE cable 7000 includes jacket 7200 that isfoamed, having substantially uniformly sized cells 7500. The foaminglevel of the jacket 7200 can be, for example, in a range of about 20% toabout 40%, such as about 30%. Further the cells 7500, which can befilled with air, can have a size (i.e., a maximum dimension) in a rangeof about 0.0005 inches to about 0.003 inches. In some cases, the foamedcells 7500 can have an average diameter of about 0.0008 inches. Further,in some embodiments, at least about 50%, or at least about 60%, or atleast about 70%, or at least about 80% of the cells 7500 have a closedstructure. PoE cable 7000 also includes a foamed separator 7001. Similarto FIG. 17A, one or both of the copper conductors of the twisted pairs7002, 7003, 7004, and 7005 in FIGS. 17B or 17C can be configured tocarry electrical data, power, or combinations thereof.

FIG. 18A schematically depicts a Power over Ethernet cable 8000according to another embodiment. The PoE cable 8000 includes a separator8001 that provides 5 longitudinal channels (8010, 8020, 8030, 8040 and8050). The separator 8001 can be in some embodiments substantially freeof halogens. Each of the channels 8010, 8020, 8030, and 8040 can haveand receive a twisted pair 8011, 8021, 8031 and 8041, respectively. Oneor both of the copper conductors of the twisted pairs 8011, 8021, 8031and 8041 can be configured to carry electrical data, power, orcombinations thereof. Also, each twisted pair 8011, 8021, 8031 and 8041can have a tape 8012, 8022, 8032 and 8042 wrapped around it. The tapecan be formed in accordance with the present teachings, as discussedherein. For example, the tape can be formed of an engineered resin. Insome embodiments, the tape is foamed. The insulation of the twistedpairs, e.g., insulation 8013 on conductor 8014 can be in someembodiments substantially fee of halogens. Similar to the otherembodiments, the cable 8000 includes two buffered optical fibers (e.g.fibers 8051 and 8052), which are enclosed within a buffer tube 8053 thatis disposed within channel 8050 of the separator 8001. The bufferedfibers 8051 and 8052 as well as the buffer tube 8053 can be formed inaccordance with the present teachings and in some cases can besubstantially free of halogens. The cable 8000 further includes an outerjacket 8002, which can also be formed in accordance with the presentteachings and can be in some cases substantially free of halogens. Insome embodiments, the insulation of the conductors and/or the jacket canbe foamed. Further, in this embodiment, the separator 8001 has a flaptop design, having flap tops 8070, partially enclosing the channels tomitigate alien crosstalk. By way of example, the cable 8000 can be usedfor plenum and riser applications.

FIG. 18B depicts an unjacketed PoE cable 8000. As described herein,channels 8010, 8020, 8030, 8040 and 8050 can contain any configurationof twisted pairs (e.g., pairs of copper conductors) and fiber opticcables. For example, as illustrated in FIGS. 18A and 18B, channels 8010,8020, 8030, and 8040 each have a twisted pairs 8011, 8021, 8031 and8041, respectively. Channel 8050 has two optical fibers 8051 and 8052.Each of the twisted pairs 8011, 8021, 8031 and 8041 can be configured tocarry electrical data, power, or combinations thereof.

FIGS. 18C and 18D depict unjacketed PoE cable 8000. Separators 8101 and8201 are foamed in accordance with the present teachings. For example,foamed separators 8101 and 8201 can have a foaming level in a range ofabout 20% to about 40%, e.g., about 30%. Cells 8102 of separator 8101can have varying sizes. Cells 8202 can have substantially uniform sizeand distribution within separator 8201. The foamed separators 8101 or8201 can comprise foamed cells having diameters in a range of about0.0005 inches to about 0.003 inches. In some cases, the foamed cells canhave an average diameter of about 0.0008 inches. The foamed cells canhave a closed cell structure, an open cell structure, or a combinationthereof. In some embodiments, a majority of the foamed cells (e.g.,greater than 50%) have a closed cell structure.

FIG. 19A depicts PoE cable 9000 according to another embodiment.Separator 9001 has a flap top design and provides 5 longitudinalchannels (9010, 9020, 9030, 9040 and 9050). Similar to the previousembodiments, the separator 9001 can comprise engineered resins and canbe solid or foamed. Channel 9050 is substantially enclosed by flap tops.Channels 9010, 9020, 9030 and 9040 are partially enclosed by flap tops9070. The separator 9001 can be in some embodiments substantially freeof halogens. Channels 9010, 9020, 9030, and 9040 each include a twistedpair 9011, 9021, 9031 and 9041, respectively. One or both of the copperconductors of the twisted pairs 9011, 9021, 9031 and 9041 can beconfigured to carry electrical data, power, or combinations thereof.Each twisted pair 9011, 9021, 9031 and 9041 can have a tape 9012, 9022,9032 and 9042 wrapped around it. The tape can be formed in accordancewith the present teachings. The insulation of the twisted pairs, e.g.,insulation 9013 on conductor 9014 can be in some embodimentssubstantially fee of halogens. The cable 9000 includes two bufferedoptical fibers (e.g. fibers 9051 and 9052), which are substantiallyenclosed by flap tops 9060 within a buffer tube 9053 that is disposedwithin channel 9050 of the separator 9001. The buffered fibers 9051 and9052 as well as the buffer tube 9053 can be formed in accordance withthe present teachings and in some cases can be substantially free ofhalogens. The cable 9000 further includes an outer jacket 9002, whichcan also be formed in accordance with the present teachings and can bein some cases substantially free of halogens. By way of example, the PoEcable 9000 can be used for plenum and riser applications.

FIG. 19B illustrates the unjacketed cable 9000 shown in FIG. 19A. Asdescribed herein, channels 9010, 9020, 9030, 9040 and 9050 can compriseany configuration and/or combination of twisted pairs (e.g., pairs ofcopper conductors) and fiber optic cables. For example, as illustratedin FIGS. 19A and 19B, channels 9010, 9020, 9030, and 9040 each have atwisted pairs 9011, 9021, 9031 and 9041, respectively. One or both ofthe copper conductors of the twisted pairs 9011, 9021, 9031 and 9041 canbe configured to carry electrical data, power, or combinations thereof.Channel 9050 has two optical fibers 9051 and 9052. Channels 9010, 9020,9030 and 9040 are partially enclosed by flap tops 9070 and channel 9050is substantially enclosed by flap tops 9060. Each of the twisted pairs9011, 9021, 9031 and 9041 can be configured to carry electrical data,power, or combinations thereof.

FIG. 19C illustrates another embodiment of the unjacketed cable 9000.Insulation 9015, 9025, 9035 and 9045 of copper conductors 9014, 9024,9034 and 9044 can be foamed in accordance with the present teachings andin some cases substantially free of halogens. The insulation of one orboth copper conductors in a twisted pair can be foamed. One or both ofthe copper conductors (e.g., conductors 9014, 9024, 9034 and 9044) ofthe twisted pairs 9011, 9021, 9031 and 9041 can be configured to carryelectrical data, power, or combinations thereof.

The PoE communications cables, cable components and articles describedherein can support the transmission of electrical power, electricaldata, fiber optic data, or combinations thereof. As depicted, forexample, in FIGS. 15-19C, a separator (e.g., 7001 in FIG. 17A) accordingto an embodiment of the present teachings can include a plurality ofchannels (e.g., channels 7200), each of which can receive at least onecopper conductor, and typically a twisted pair of copper conductors. InFIG. 15, copper pairs 5010, 5011, 5012 and 5013 can be each configuredto carry electrical power. For example, electrical conductors (e.g.,copper cables) 5010, 5011, 5012, and/or 5013 can carry 0 to about 25watts of power. In some aspects, each electrical conductor can carryabout 1 watt, about 5 watts, about 10 watts, about 15 watts, about 20watts, about 25 watts, or about 30 watts of power. The total power thatis carried by a single communications cable is equal to the sum of thepower carried by the individual copper cables. In some aspects, thetotal power carried by the electrical conductors in a singlecommunication cable described herein is about 1 watt to about 300 watts,e.g., about 1 watt, about 10 watts, about 20 watts, about 50 watts,about 75 watts, about 100 watts, about 150 watts, about 200 watts, orabout 300 watts.

In some embodiments, the electrical conductors can have an AWG (AmericanWire Gauge) in a range of about 22 to about 26. In some aspects, eachelectrical conductor can support an electrical current (ampere) in therange of about 1 milliamp (mA) to about 2 amps (A). Additionally oralternatively, each electrical conductors can be maintained at anelectrical potential in the range of about 1 volt to about 240 volts.

As described herein, power over Ethernet (PoE) cables allow power to betransmitted over long cable lengths. The power can be carried on thesame conductors as the data, or it may be carried on dedicatedconductors in the same cable. In some aspects, some or all of the coppercables present in a communications cable according to the presentteachings can carry electrical power. There are several commontechniques for transmitting power over Ethernet cabling. For example,two of these techniques have been standardized by IEEE 802.3. Since onlytwo of the four pairs are needed for 10 BASE-T or 100 BASE-TX, power canbe transmitted on the unused conductors of a cable. This is referred toas Alternative B (IEEE). The leading number (“10” in 10 BASE-T) refersto the transmission speed in Mbit/s. “BASE” denotes that basebandtransmission is used. The “T” designates twisted pair cable. Where thereare several standards for the same transmission speed, they aredistinguished by a letter or digit following the T, such as “TX.”

Alternatively, power can be transmitted on the data conductors byapplying a common-mode voltage to each pair. Since twisted-pair Ethernetuses differential signaling, this does not interfere with datatransmission. The common mode voltage is extracted using the center tapof the standard Ethernet pulse transformer. This is similar to thephantom power technique commonly used for powering audio microphones.This is referred to as Alternative A.

Accordingly, a communications cable (e.g., see FIGS. 15, 16, 17A-17C,18A-18D, or 19A-19C) can be configured so that some (at least one) orall of the electrical (e.g., copper) conductors carry electrical power.In some embodiments, at least one electrical (e.g., copper) conductor,or conductor pair, carries electrical power. In some embodiments, atleast 2 electrical (e.g., copper) conductors, or conductor pairs, carryelectrical power. In some embodiments, at least 3 electrical (e.g.,copper) conductors, or conductor pairs, carry electrical power. In someembodiments, at least 4 electrical (e.g., copper) conductors, orconductor pairs, carry electrical power.

Also, a communications cable can be configured so that some (at leastone) or all of the electrical (e.g., copper) conductors carry electricalpower and electrical data on the same conductor. For example, in acommunications cable having 4 copper conductor pairs (e.g., twistedcopper pairs 7002, 7003, 7004, and/or 7005 in FIG. 17), 1, 2, 3 or 4 ofthe copper conductors can each carry electrical power (e.g., DC power)along with electrical data.

Table 5 below, adapted from IEEE 802.3-2005, section 2, table 33-3,shows the power range for each class, defined by IEEE.

TABLE 5 Power Levels for PoE Class Current (mA) Power range (Watts)4-Pair Cable (total watts) 0 0-4  0.44-12.94 51.76 1  9-12 0.44-3.8415.36 2 17-20 3.84-6.49 25.96 3 26-30  6.49-12.95 51.8 4 36-4412.95-25.5  102

For example, the communication cables described herein can fully supportand power any number of PoE devices, such as voice over IP (VoIP) andwireless networking (WLAN) devices. For VoIP applications, DC power istransmitted along with data. For WLAN applications, it may beimpractical or expensive to run AC power at certain access points. Theability to use the same cable for data and power decreases the cost ofdeploying IP technology.

Other examples of devices capable of using PoE include, but is notlimited to industrial control/automation, lighting, flat screen TV's,security systems, video/surveillance cameras, media hubs, smart phonemedia control, fire protection, environmental monitoring, extendedwireless networks, and artificial intelligence that stabilizes andoptimizes networks, heating/cooling (HVAC) systems.

In some embodiments, the communications cables described herein arecapable of carrying data (network) transmission and power transmission.For example, the communications cable according to some embodiments cancomply with TIA 568-C.2 and ISO 11801 specifications. These cables aredesigned specifically for data transmission and utilize copperconductors that are typically 22-26 AWG (American Wire Gauge). Powercables, for example, used in buildings can be about 12-14 AWG. Asdescribed herein, the cables can have a balance of power transmissionand data transmission while maintaining the safety standards, outlinedin Table 2, above.

A current carried by an electrical conductor can cause heating of theconductor in accordance with the following relationship:I²Rt=H

where:

R denotes electrical resistance of the conductor;

I denotes current carried by the conductor;

t denotes the time period during which the current has been carried bythe conductor and;

H denotes heat generated in the conductor.

By way of example, the resistivity of copper increases as the circularmils of the conductor is reduced. Smaller wires, for example those usedin data cables, produce more heat than, for example, typical powerwiring. Also, resistivity increases as the temperature of the copperconductor increases. Accordingly, in some aspects, the communicationcables described herein comply with TIA 568-C.2 and ISO 11801 cablingstandards, wherein conductors utilized in balanced twisted pair cablecan be in accordance with ASTM D4566 and shall not exceed 9.38Ω/100meters (328 ft.).

Thermal conductivity is the amount of heat a material can carry throughit in unit time. Thermal conductivity is expressed in W/(mk); watts permeter kelvin. Thermal Conductivity (often denoted k, λ, or κ) isevaluated primarily in terms of Fourier's Law for Heat Conduction. Forexample, heat transfer occurs at a lower rate across materials of lowthermal conductivity than across materials of high thermal conductivity.The reciprocal of thermal conductivity is called thermal resistivity.

Air bubbles in dielectric materials of a cable can provide increasedthermal resistivity, thus reducing the heat transfer from the conductorsto other areas of the cable, such as other insulated conductors,fillers, tapes (including shielding tapes) and jackets. Thermalconductance is additive, so thermal resistivity is additive inverse.Because thermal resistivity is additive inverse each additional foamedcomponent that is added further reduces the amount of heat energy thatis transferred to the next layer or area surrounding the cable or bundleof cables. For example, a cable comprising a foamed insulation cantransfer less heat than a cable comprising non-foamed insulation. Acable comprising both a foamed insulation and a foamed jacket canprovide less heat transfer than a cable with only foamed insulations. Acable comprising a foamed insulation, a foamed filler such as a crossweb, tape, woven or non-woven material, and a foamed jacket can provideless heat transfer than the non-foamed products. Shielded cablescomprising foamed insulation, foamed shielding tape, with or withoutadditional fillers and a foamed jacket can provide less heat transferthan other non-foamed or partial foamed cable constructions.

Existing PoE and newer requirements, described herein, requireconductors to carry higher currents. As shown above, as currentincreases, the temperature of the copper conductor increases. In somecases, an increase in the conductor's temperature can require the use ofa thermal insulator, e.g., a material having a high thermal resistivity,to reduce, and preferably inhibit, transfer of heat from the conductorto adjacent components of the cable. This can be important becausetransferring excessive heat can affect other materials in the cable,such as drying the plasticizer out of PVC materials, which can cause theaffected material to become brittle and decrease the life of the cablewhile also increasing the risk of electrical fires.

Table 6, below, provides examples of twisted pair data transmissioncable and the most common twisted-pair cables.

TABLE 6 Examples of Twisted Pair Data Transmission Cable Typicalconstruc- Name tion Bandwidth Applications Level 1 0.4 MHz Telephone andmodem lines Level 2 4 MHz Older terminal systems, e.g. IBM 3270 Cat. 3UTP 16 MHz 10BASE-T and 100BASE- T4Ethernet Cat. 4 UTP 20 MHz 16 Mbit/sToken Ring Cat. 5 UTP 100 MHz 100BASE-TX & 1000BASE- TEthernet Cat. 5eUTP 100 MHz 100BASE-TX & 1000BASE- TEthernet Cat. 6 UTP 250 MHz10GBASE-T Ethernet Cat. 6_(A) U/FTP, 500 MHz 10GBASE-T Ethernet F/UTPCat. 7 F/FTP, 600 MHz 10GBASE-T Ethernet.POTS/ S/FTP CATV/1000BASE-Tover single cable Cat. 7_(A) F/FTP, 1000 MHz 10GBASE-T Ethernet.POTS/S/FTP CATV/1000BASE-T over single cable Cat. 8/8.1 U/FTP, 1600-2000 MHz40GBASE-T Ethernet.POTS/ F/UTP CATV/1000BASE-T over single cable Cat.8.2 F/FTP, 1600-2000 MHz 40GBASE-T Ethernet.POTS/ S/FTP CATV/1000BASE-Tover single cable

Table 7, below, provides examples of common industry abbreviations, asused herein. In Table 7, under column “TIA; ISO 11801,” the code beforethe slash designates the shielding for the cable itself, while the codeafter the slash determines the shielding for the individual pairs:

U=unshielded

F=foil shielding

S=braided shielding (outer layer only)

TP=twisted pair

TABLE 7 Common Industry Abbreviations for Cable Construction Industryacronyms TIA; ISO 11801 Cable shielding Pair shielding UTP U/UTP nonenone STP, ScTP, PiMF U/FTP none foil FTP, STP, ScTP F/UTP foil none STP,ScTP S/UTP braiding none SFTP, S-FTP, STP SF/UTP braiding, foil noneFFTP F/FTP foil foil SSTP, SFTP, STP S/FTP braiding foil PiMF SSTP, SFTPSF/FTP braiding, foil foil

Table 8, below, illustrates various materials used in communicationcables and their associated thermal conductivity.

TABLE 8 Various Materials Used in Data Cables and their associatedThermal Conductivity: Material Description Thermal Conductivity AirGaseous Mixture 0.026 Copper Non-Ferrous Conductive Metal 401 PEEKPolyether Ether Ketone 0.25 PES Polyethersulfone 0.15 PPSUPolyphenylsulfone 0.35 PSU Polysulphone 0.35 PEI Polyetherimide 0.22

The foaming of plastic materials (e.g., of one or more engineeredresins), can allow heat to dissipate through convection more quickly.For example, the thermal conductivity of PEEK with the addition of airto the dielectric is calculated:

PEEK:  0.25 × 70% = 0.175 Air: 0.026 × 30% = 0.0078 =0.1828

In the calculation above, the sum of the thermal conductivities of therelative contributions from PEEK and air is calculated. In this example,a 30% foam level was assumed, i.e., air contributes 30% and PEEKcontributes 70%.

Table 9, below, lists the thermal conductivity of various polymers.Using the thermal conductivity of air, the overall thermal conductivityof the material is calculated at both a 30% foam level and a 50% foamlevel.

TABLE 9 Material Thermal Conductivity Material Thermal Cond. ThermalCond. Air 30% Foam 50% Foam PEEK 0.25 0.026 0.1828 0.138 PES 0.15 0.0260.1128 0.088 PEI 0.22 0.026 0.1618 0.123 PSU 0.35 0.026 0.2606 0.188PPSU 0.35 0.026 0.2606 0.188

As shown in Table 9, the addition of air to a material reduces thethermal conductivity and increases thermal resistivity. Besides theprocess of foaming, any method of adding air to materials can reduce thethermal conductivity and can increase the thermal resistivity.

Thus, it is an aspect of the invention described herein, that theaddition of air (e.g., through foaming) to a polymeric dielectricmaterial such as those used in the cable construction described herein,to reduce the heat transfer and/or increase the heat resistivity of thematerial.

Accordingly, as described herein, foamed insulations, foamed fillers,foamed tapes, foamed jackets, and/or foamed separators can reduce theamount of heat released to areas surrounding the cable or bundle ofcables due to increased thermal resistivity. Since thermal resistivityis the reciprocal of heat transfer, the addition of a foamed materialinto a cable construction further reduces heat transfer to surroundingareas. Also, reducing the heat transfer to outer layers of the cable andareas surrounding increases the fire safety of the cable.

Therefore, it is an aspect of the present teachings to increase thethermal resistivity of a communications cable and/or components ofcommunications cables (e.g., insulation, filler, tape, jacket, and/orseparator). Further, construction of communication cables and componentsof communication cables with increased thermal resistivity can reducethe amount of heat that cable will absorb from its environment(surroundings). Particular environments where this type ofcommunications cable would be useful, includes, for example, hightemperature areas using cabling in industrial applications, plenum areasin which extreme heat is normal, down hole applications. As describedherein, increasing the thermal resistivity can be from, for example,foaming the polymeric materials. It is also another aspect to reduce thefuel in a communications cable. Also, it is an aspect to reduce theamount of peak smoke and average smoke in the communication cablesdescribed herein that can be emitted during Safety testing such as NFPA262 Standard Method of Test for Flame Travel and Smoke of Wires andCables for use in Air-Handling Spaces.

ANSI/TIA 568-C.2 (Table G3) provides well known guidelines for de-ratingcable length based on increased insertion loss for temperature rise ofboth unscreened and screened cables. This table is primarily for cablesinstalled in high temperature environments. The same effect ontransmission can be seen through radiant heating of conductors due toincreased current. Lower thermal conductivity of cable materials canreduce insertion loss allowing a signal to travel farther. In fixedinstallations running active Ethernet protocol increasing heat of thecable will reduce the length of the signal by increasing insertion lossthus increasing the possibility of lost packets of information (BITError Rate). The loss of ethernet packets cause systems to resendinformation thus lowering the network's efficiency.

Formula from ANSI/TIA 568-C.2—Annex GIL₂₀=IL_(t)/1+δ₁(T−20)+1+δ₂(T−40)

Where:

IL_(t)=Measured insertion loss at temperature T

IL₂₀=Insertion loss corrected to 20° C.

T=Measured temperature in ° C.

TABLE 10 Maximum horizontal cable length de-rating for differenttemperatures (Annex G; TIA 568-C.2) Temperature (° C.) δ₁ δ₂ UTP 20 ≤ T≤ 40 0.0004 0 40 ≤ T ≤ 60 0.0004 0.00248 F/UTP 20 ≤ T ≤ 60 0.002 0

Below are examples of Power over Ethernet formats.

POE per IEEE 802.af maximum power 15.4 Watts, max current 350 mA

POE+ per IEEE 802at Type 2 maximum power 30 Watts, max current 600 mA

UPOE per IEEE 802.3at −2009 maximum power 60 Watts, max current 1 AMP

HDBaseT (50 W+50 W) maximum power 200 Watts, max current 1 AMP, beingdefined

TABLE 11 Converting Watts to ° C./hr Watts ° C./hr POE 15.4 8.12 POE+ 3015.83 UPOE 60 31.65 HDBaseT 200 105.51 Watts = 0.52752793° C./hr

While the production of heat by conductor resistivity and amperage canover time effect safety of cabling it can also cause problems thatrelate to physical termination between the wire conductor and theconnector terminal. Tin plating on copper conductors, which reach 85° C.(185° F.), is the most common cause of fretting corrosion in tin platedconnectivity systems. It is well known by those skilled in the art thatfretting corrosion breaks the gas tight seal between the conductorplating and the connector plating thus increasing resistance and heat inthat area, which can result in excessive heat to the point of creatingfire and burning the connector. Even when the heat is not sufficient tocause a fire it can cause the connector housing to age prematurely,becoming brittle and not providing proper circuit protection. Foamingthe plastic housings of the connectivity system will also promoteefficient convection cooling, thus, reducing the possibilities of thisoccurrence. If the foamed connectivity housings use the same materialsas the foamed insulation it will promote better data transmission byproviding less impedance variation.

Electrically Conductive Elements

FIG. 22 schematically depicts a polymeric composition 1, e.g. a pellet,according to an embodiment of the invention that includes a polymer baseresin 2 in which a plurality of electrically conductive inclusions 3 aredispersed. In some embodiments, the polymer base resin includes at leastabout 50 weight percent of the composition. For example, the polymerbase resin can include about 50 to about 95 weight percent of thecomposition, or about 60 to about 85 weight percent, or about 60 weightpercent to about 80 weight percent, or about 60 weight percent to about75 weight percent, of the polymeric composition. The polymer base resincomprises any of polyphenylenesulfide (PPS), polyetherimide (PEI),polysulfone (PSU), polypheylsulfone (PPSU), polyethersulfone (PES/PESU),polyetheretherketone (PEEK), polyaryletherketone (PAEK),polyetherketoneketone (PEKK), polyetherketone (PEK), or polyolefins suchas polyethylene (PE), polyproplylene (PP), cyclic olefin copolymer(COC), polycarbonate (PC), polyphenylene ether (PPE), liquid crystalpolymer (LCP), and/or combinations thereof. In some embodiments, thepolymeric composition is substantially free of halogens.

In some embodiments, the electrically conductive inclusions 3 caninclude about 1 weight percent to about 30 weight percent, or about 5weight percent to about 20 weight percent, or about 5 weight percent toabout 15 weight percent, or about 5 weight percent to about 10 weightpercent of the polymeric composition.

In some embodiments, the electrically conductive inclusions 3 cancomprise any of metal, metal oxide, or other electrically conductivematerials, such as carbon nanotubes carbon fullerenes, carbon fibers,nickel coated carbon fibers, single or multi-wall graphene, or copperfibers. By way of example, in some embodiments the electricallyconductive inclusions 3 include any of silver, aluminum, copper, gold,bronze, tin, zinc, iron, nickel, indium, gallium, or stainless steel. Insome embodiments the electrically conductive inclusions 3 can includemetal alloys, such as, for example, tin alloys, gallium alloys, or zincalloys. In other embodiments, the electrically conductive inclusions caninclude metal oxides, such as, for example, copper oxide, bronze oxide,tin oxide, zinc oxide, zinc-doped indium oxide, indium tin oxide, nickeloxide, or aluminum oxide. In some embodiments, some of the electricallyconductive inclusions are formed of one material while others are formedof another material. Further, in some embodiments, the electricallyconductive inclusions are formed of metals and are substantially free ofany metal oxides.

The electrically conductive inclusions 3 can have a variety of shapes.For example, in some embodiments, the electrically conductive inclusionsare in the form of discrete particles having a variety of geometricalshapes. For example, the electrically conductive inclusions can compriseparticles having any of spherical, needle-like, or flake-like shapes. Insome other embodiments, the electrically conductive inclusions 3 are inthe form of agglomerates of an electrically conductive material withouta defined geometrical shape.

The electrically conductive inclusions can have a variety of sizes andaspect ratios. By way of example, the electrically conductive inclusionscan include needle-like particles having an aspect ratio in a range ofabout 10 to about 1000. In some embodiments, the electrically conductiveinclusions can have a maximum size in a range of about 10 microns toabout 6000 microns, or in a range of about 600 microns to about 6000microns, or in a range of about 10 microns to about 600 microns. By ofexample, the electrically conductive inclusions can include needle-likeparticles having a length in a range of about 10 microns to about 6000microns or in a range of about 600 microns to about 6000 microns, or ina range of about 10 microns to about 600 microns. Alternatively or inaddition, the electrically conductive inclusions can include sphericalparticles having a diameter in a range of about 10 microns to about 6000microns, or in a range of about 600 microns to about 6000 microns, or ina range of about 10 microns to about 600 microns. In other embodiments,the electrically conductive inclusions can include flake-like particleshaving a maximum cross-sectional dimension in a range of about 10microns to about 6000 microns, or in a range of about 600 microns toabout 6000 microns, or in a range of about 10 microns to about 600microns.

In some embodiments, the electrically conductive inclusions can includeparticles of different shapes. For example, the electrically conductiveinclusions can include particles having two different shapes. In somesuch embodiments, one type of the particles are particularly suitablefor reflecting electromagnetic radiation incident thereon, e.g.,electromagnetic radiation having a frequency in a range of about 1 MHzto about 40 GHz or in a range of about 1 MHz to about 10 GHz, or in arange of about 1 MHz to about 2 GHz, or in a range of about 1 MHz toabout 1.5 GHz, and the other type of particles are particularly suitablein dissipating (e.g., via heat generation or eddy current generation)the electromagnetic radiation incident thereon, e.g., electromagneticradiation having a frequency in a range of about 1 MHz to about 40 GHzor in a range, of about 1 MHz to about 10 GHz, or in a range of about 1MHz to about 2 GHz, or in a range of about 1 MHz to about 1.5 GHz.

For example, in some embodiments, the polymeric composition 1 caninclude a plurality of needle-like metallic particles and a plurality offlake-like metallic particles. In some such embodiments, the needle-likemetallic particles can primarily reflect the incident electromagneticradiation having one or more frequencies in a range of about 1 MHz toabout 10 GHz and the flake-like metallic particles can primarilydissipate (e.g., via absorption) the incident electromagnetic radiationhaving frequencies in a range of about 1 MHz to about 10 GHz. In somesuch embodiments, the fraction of particles having needle-like shaperelative to those having a flake-like shape, or vice versa, can beabout, e.g., 50/50, 40/60, 30/70, 20/80, or 10/90.

In some embodiments, the base polymer can comprise at least about 50weight percent, or at least about 60 weight percent, or at least about70 weight percent, or at least about 80 weight percent, or at leastabout 90 weight percent or at least about 95 weight percent of thecomposition. The electrically conductive inclusions can in turn compriseat least about 1 weight percent, or at least about 2 weight percent, orat least about 3 weight percent, or at least about 4 weight percent, orat least about 5 weight percent, or at least about 6 weight percent, orat least about 7 weight percent, or at least about 8 weight percent, orat least about 9 weight percent, or at least about 10 weight percent, orat least about 15 weight percent, or at least about 20 weight percent ofthe composition. For example, the electrically conductive inclusions cancomprise about 1 weight percent to about 20 weight percent of thecomposition. Further, the chemical foaming agent can comprise at leastabout 1 weight percent, or at least about 2 weight percent, or at leastabout 3 weight percent, or at least about 4 weight percent, or at leastabout 5 weight percent, or at least about 6 weight percent, or at leastabout 7 weight percent, or at least about 8 weight percent, or at leastabout 9 weight percent, or at least about 10 weight percent, or at leastabout 15 weight percent, or at least about 20 weight percent, or atleast about 30 weight percent, of the composition.

In some embodiments, the electrically conductive inclusions are formedof a metal, in other embodiments the inclusions 86 can be formed of ametal oxide, such as, for example, copper oxide, bronze oxide, tinoxide, zinc oxide, zinc-doped indium oxide, indium tin oxide, nickeloxide, or aluminum oxide. In other embodiments, the electricallyconductive inclusions can be formed of carbon nanotubes, graphene,and/or fullerenes. As known in the art, carbon nanotubes are allotropesof carbon with a cylindrical nanostructure. Nanotubes are members of thefullerene structural family, which also includes the sphericalbuckyballs, and the ends of a nanotube may be capped with a hemisphereof the buckyball structure.

In some embodiments, rather than or in addition to distributing metalinclusions within, for example, a separator, an outer surface of aseparator can be coated with an electrically conductive material, e.g.it can be metalized, to provide electromagnetic shielding. By way ofexample, FIG. 23A schematically depicts an embodiment of such aseparator 96, which has a polymeric body portion 98 having a T-shapedcross-sectional profile. A thin metal coating 100 covers an outersurface of the body portion 98 to provide electromagnetic shielding. Insome embodiments, a thickness of the metal coating can be, e.g., in arange of about 3 microns to about 12 microns. While in some embodiments,the metal coating has a substantially uniform thickness, in otherembodiments, the thickness of the metal coating can exhibit a variationover the surface on which it is deposited. A number of metals can beutilized to form the coating 100. By way of example, the metal coatingcan be formed of any of copper, silver, aluminum, copper, gold, bronze,tin, zinc, iron, nickel, indium, gallium, or stainless steel. In someembodiments, a plurality of electrically conductive inclusions (e.g.,metal inclusions), discussed in more detail above, can be distributedwithin the polymeric body portion 98.

While in this embodiment, the metal coating 100 covers substantially theentire outer surface of the body portion 98, in other embodiments, themetal coating can cover only portions of the outer surface. By way ofexample, FIG. 23B schematically depicts a separator 97 according toanother embodiment having a metal coating that is in the form of apatchwork of metal portions 101 deposited on the outer surface of apolymeric body portion 99 of the separator. In this embodiment, theseparator includes an engineered resin (or a mixture of two or moreengineered resins) and is preferably substantially free of a halogen.Again, the thickness of each metal portion can be, e.g., in a range ofabout 3 microns to about 12 microns. In some cases, the metal portionscover at least about 30%, or at least about 40%, or at least about 50%,or at least about 60%, or at least about 70%, or at least about 80%, orat least about 90%, or at least about 95% of the surface area of theseparator. In some embodiments, a plurality of electrically conductiveinclusions, e.g., metal inclusions, can be distributed within thepolymeric body portion 99.

The coating of conductive material can be applied using any suitableprocess known in the art. For example, the coating can be applied usinga process of electroless plating. Other processes that can be used toapply the coating of conductive material can include, for example,electroplating, vacuum deposition, sputter coating, double-side plating,single-side plating. In some embodiments, the coating can be applied asa film or foil bonded or otherwise attached to or disposed on theseparator. In other embodiments, the coating can be applied by passingthe separator through a metal bath, e.g., a tin, bismuth-tin blend, orindium alloy bath.

FIG. 24 schematically depicts a separator 100 according to anotherembodiment of the invention that includes a polymeric body portion 102,which includes one or more engineered resins, having a T-shaped crosssection, which provides 4 channels in which conductors can be disposed.The separator 100 further includes an electrically conductive strip 102(e.g., a metal strip) that is disposed internally within the bodyportion 101. In this embodiment, the metal strip extends along thelength of the separator from a proximal end to a distal end thereof toprovide electromagnetic shielding between conductors (not shown)disposed within the channels formed by the separator. In someembodiments, a thickness of the internal metal strip can be in a rangeof about 6 microns to about 55 microns.

Methods of Manufacturing and Making Foamed Articles

In one aspect, methods of fabricating foamed articles by processingfoamable compositions according to the present teachings are disclosed.In one embodiment, a foamable composition according to the presentteachings, such as the foamable compositions described above, isprocessed at an elevated temperature to cause foaming of the talc (ortalc derivative) (that is, the disintegration of talc to generate gases)so as to foam the composition. By way of example, the processing of thefoamable composition can be performed at a temperature of at least about600° F., at least about 620° F., at least about 630° F., at least about640° F., or at least about 650° F. The processing of the foamablecomposition can be performed in a variety of different ways. Forexample, the foamable composition can be extruded at an elevatedtemperature to generate a foamed article.

In some embodiments, the processing parameters are selected such thatthe foamed article exhibits a foaming level of about 10% to about 80%,e.g., in a range of about 15% to about 70%, or in a range of about 20%to about 60%, or in a range of about 25% to about 50%, or in a range ofabout 30% to about 40%. In some embodiments, the foaming level is about10%, about 15%, about 20%, about 25%, about 30%, about 35%, about 40%,about 45%, about 50%, about 55%, about 60%, about 65%, about 70%, about75%, or about 80%.

In some embodiments, the methods described herein can include the use ofa twin-screw extruder for melting, blending and pelletizing. In someaspects, the compounding process utilizes a two-step system to ensurethe foaming components are thoroughly distributed and dispersed in thebase polymer of the final compound. In some embodiments, the first stepincludes foaming a masterbatch blend of one or more foaming agents. Thefoaming agents can be in the form of fine powder. A high intensityblender, (i.e. Henschel type) can be used to prepare the powder blendaccording to the specified formulation. A certain amount of resin, alsoin powder form, can be used in the first blending step as a mechanism topredisperse the foaming agents and facilitate the second extrusioncompounding step.

The second stage of the compound preparation process can utilize a twinscrew extrusion compounding system to incorporate the foaming agentmasterbatch blend with the base resin. The design of the compoundingscrew is such that there is sufficient heat and mechanical energy tofully thermally melt the base polymer and incorporate the masterbatchblend with proper distribution and dispersion during mixing forhomogeneity, but yet mild enough to keep the processing temperature ofthe compound below that in which foaming may be prematurely initiated.The final compound can be strand extruded and pelletized oralternatively an underwater pelletizing technique may be used (in otherwords air or water cooling is acceptable).

EXAMPLES

The following examples are provided for further illustration of variousaspects of the present teachings, and are not necessarily intended toindicate optimal ways of practicing the invention.

All of the materials were determined to be halogen-free based on theUnderwriter's Laboratories, (U.L. 2885) protocol:

IEC 60754-1, Test on gases evolved during combustion of materials fromcables—Part 1: Determination of the halogen acid gas content and/or;

IEC 60754-2, and/or “Test on Gases Evolved During Combustion ofMaterials from Cables—Part 2: Determination of acidity (By pHMeasurement) and Conductivity.”

Draft IEC 62821-1 “Halogen free low smoke thermoplastic insulated andsheathed cables of rated voltages up to and including 450/750 V.

Specific gravity (S_(g)) tests were performed both on the solid andcompounded pellet to ASTM D792. The tensile and elongation testing wasperformed to ASTM D638. The method for measuring the foam by the weightmethod involved extruding a 10 foot foamed sample and dividing thatweight by the theoretical 10 foot weight of a solid sample. The methodfor measuring the foam by the specific gravity included using ASTM D792to obtain the specific gravity of the sample and dividing that by thespecific gravity of the solid pellets. Talc utilized in the followingexamples was obtained from D. N. Lukens under trade designation ArticMist (AMPXXPNBJ). In all of the following examples, the ratios providedare weight ratios.

Example 1 PSU

Manufacture of a Pelletized Foamable Composition

PSU, in a weight ratio of Aclyn® wax or Genioplast Silicone or DowCorning Si Powder Resin, halogen-free, powdered siloxane, Dow Corning4-7105 or 4-7081/talc/non-halogenated resin 0.25/7.5/92.25 was formed bysequential additions through a feeder section of a twin screw extruder.Temperature profile in the melt twin screw extruder was the following(from zone 1 to 11): 475° F., 550° F. (288° C.), 550° F. (288° C.), 550°F. (288° C.), 525° F. (274° C.), 480° F. (249° C.), 525° F. (274° C.),500° F. (260° C.), 500° F. (260° C.), 500° F. (260° C.), 575° F. (302°C.). The extruder was equipped with a pelletizer to produce pellets to ashape that is preferable for extrusion processes.

Example 2 PSU

Manufacture of a PSU, Wax, and Talc Derivative (Masterbatch Composition)

Aclyn® wax or Genioplast Silicone or Dow Corning Si Powder Resin,halogen-free, powdered siloxane, Dow Corning 4-7105 or 4-7081commercially available from M. F. Cachat and a talc derivative ofchemical composition Mg₃Si₄O₁₀(OH) was melt compounded with anon-halogenated resin, namely PSU, in a weight ratio of Aclyn® wax orGenioplast Silicone or Dow Corning Si Powder Resin, halogen-free,powdered siloxane, Dow Corning 4-7105 or 4-7081/talc/non-halogenatedresin 0.25/15.0/84.75, in a twin screw extruder, with the followingtemperature profile: 475° F., 550° F. (288° C.), 550° F. (288° C.), 550°F. (288° C.), 525° F. (274° C.), 480° F. (249° C.), 525° F. (274° C.),500° F. (260° C.), 500° F. (260° C.), 500° F. (260° C.), 575° F. (302°C.).

Example 3 PSU

Manufacture of Foamed Articles from a Mixture of Pellets

Pellets obtained from example 1 or pellets obtained from example 2,blended with PEI at a weight ratio of 50/50, are then placed in thehopper of a 24 to 1 ratio high temperature extruder with heat zones 1through 6 set at the following temperatures 500° F. (260° C.), 522° F.(272° C.), 600° F. (316° C.), 617° F. (325° C.), 644° F. (340° C.), and565° F. (296° C.) to form one of several foamed articles including anextruded profile such as used for separators, wire insulation, orjackets for cabling.

Foamed articles were found to possess an outstanding cells structure,with tunable foaming level, and outstanding insulating properties asdescribed in the following examples.

Example 4 PSU

A tape cable support-separator was manufactured with a 1.5 inch hightemperature extruder using the following materials and conditions:

A tape die with a high compression screw, a line speed of 361 ft./min.,with a 16 RPM screw speed and a melt temperature of 625 F (330° C.) wasused. The extruder was loaded with a pellet master batch, the pelletsconsisted of 7.5% talc, 0.25% Aclyn® wax or Genioplast Silicone or DowCorning Si Powder Resin, halogen-free, powdered siloxane, Dow Corning4-7105 or 4-7081 and 82.25% PEI. The pellet master batch was not blendeddown, but rather was used at 100%. This resulted in an extruded tapethat was 44% foamed with an average foamed cell size of 0.0007 inches.

Example 5 PPS

Manufacture of a Pelletized Foamable Composition

A mixture of a non-halogenated resin, namely PPS, talc and Aclyn® wax orGenioplast Silicone or Dow Corning Si Powder Resin, halogen-free,powdered siloxane, Dow Corning 4-7105 or 4-7081 in a weight ratio ofAclyn® wax or Genioplast Silicone or Dow Corning Si Powder Resin,halogen-free, powdered siloxane, Dow Corning 4-7105 or4-7081/talc/non-halogenated resin 0.25/7.5/92.25 was formed bysequential additions through feeder section of the twin screw extruder.Temperature profile in the melt twin screw extruder was the following(from zone 1 to 11): 475° F., 550° F. (228° C.), 550° F. (228° C.), 550°F. (228° C.), 525° F. (274° C.), 480° F. (249° C.), 525° F. (274° C.),500° F. (260° C.), 500° F. (260° C.), 500° F. (260° C.), 575° F. (302°C.). The extruder was equipped with a pelletizer to produce pellets to ashape that is preferable for extrusion processes.

Example 6 PPS

Manufacture of a PEI, Wax, and Talc Derivative (Masterbatch Composition)

Aclyn® wax or Genioplast Silicone or Dow Corning Si Powder Resin,halogen-free, powdered siloxane, Dow Corning 4-7105 or 4-7081commercially available from M. F. Cachat and a talc derivative ofchemical composition Mg3Si4O10(OH) was melt compounded with anon-halogenated resin, namely PPS, in a weight ratio of Aclyn® wax orGenioplast Silicone or Dow Corning Si Powder Resin, halogen-free,powdered siloxane, Dow Corning 4-7105 or 4-7081/talc/non-halogenatedresin 0.25/15.0/84.75, in a twin screw extruder, with the followingtemperature profile: 475° F., 550° F. (228° C.), 550° F. (228° C.), 550°F. (228° C.), 525° F. (274° C.), 480° F. (249° C.), 525° F. (274° C.),500° F. (260° C.), 500° F. (260° C.), 500° F. (260° C.), 575° F. (302°C.).

Example 7 PPS

Manufacture of Foamed Articles from a Mixture of Pellets;

Pellets obtained from example 1 or pellets obtained from example 2,blended with PPS at a weight ratio of 50/50, were placed in the hopperof a 24 to 1 ratio high temperature extruder with heat zones 1 through 5set at the following temperatures: 520° F. (321° C.), 540° F. (332° C.),560° F. (343° C.), 570° F. (349° C.), and 560° F. (343° C.) to form oneof several foamed articles including an extruded profile such as usedfor separators, wire insulation, or jackets for cabling.

The foamed articles were found to possess an outstanding cellsstructure, with tunable foaming level, and outstanding insulatingproperties as described in the following examples.

Example 8 PPS

A tape cable support-separator was manufactured with a 1.5 inch hightemperature extruder using the following materials and conditions:

A tape die with a high compression screw, a line speed of 48 ft./min.,with a 4 RPM screw speed and a melt temperature of 536° F. (280° C.) wasused. The extruder was loaded with a pellet master batch, the pelletcomprising 7.5% talc, 0.25% Aclyn® wax or Genioplast Silicone or DowCorning Si Powder Resin, halogen-free, powdered siloxane, Dow Corning4-7105 or 4-7081 and 82.25% PPS. The pellet master batch was not blendeddown, but rather was used at 100%. This resulted in an extruded tapethat was 39% foamed with an average foamed cell size of 0.0007 inches.

Example 9 PEEK

Manufacture of a Pelletized Foamable Composition

A mixture of a non-halogenated resin, namely PEEK, talc and Aclyn® waxor Genioplast Silicone or Dow Corning Si Powder Resin, halogen-free,powdered siloxane, Dow Corning 4-7105 or 4-7081 in a weight ratio ofAclyn® wax or Genioplast Silicone or Dow Corning Si Powder Resin,halogen-free, powdered siloxane, Dow Corning 4-7105 or4-7081/talc/non-halogenated resin 0.25/7.5/92.25 was formed bysequential additions through feeder section of a twin screw extruder.Temperature profile in the melt twin screw extruder was the following(from zone 1 to 11): 475° F., 550° F. (228° C.), 550° F. (228° C.), 550°F. (228° C.), 525° F. (274° C.), 480° F. (249° C.), 525° F. (274° C.),500° F. (260° C.), 500° F. (260° C.), 500° F. (260° C.), 575° F. (302°C.). The extruder was equipped with a pelletizer to produce pellets to ashape that is preferable for extrusion processes.

Example 10 PEEK

Manufacture of a PEI, Wax, and Talc Derivative (Masterbatch Composition)

Aclyn® wax or Genioplast Silicone or Dow Corning Si Powder Resin,halogen-free, powdered siloxane, Dow Corning 4-7105 or 4-7081commercially available from M. F. Cachat and a talc derivative ofchemical composition Mg₃Si₄O₁₀(OH) was melt compounded with anon-halogenated resin, namely PEEK, in a weight ratio of Aclyn® wax orGenioplast Silicone or Dow Corning Si Powder Resin, halogen-free,powdered siloxane, Dow Corning 4-7105 or 4-7081/talc/non-halogenatedresin 0.25/15.0/84.75, in a twin screw extruder, with the followingtemperature profile: 475° F., 550° F. (228° C.), 550° F. (228° C.), 550°F. (228° C.), 525° F. (274° C.), 480° F. (249° C.), 525° F. (274° C.),500° F. (260° C.), 500° F. (260° C.), 500° F. (260° C.), 575° F. (302°C.).

Example 11 PEEK

Manufacture of Foamed Articles from a Mixture of Pellets;

Pellets obtained from example 1 or pellets obtained from example 2,blended with PEEK at a weight ratio of 50/50, were placed in the hopperof a 24 to 1 ratio high temperature extruder with heat zones 1 through 6set at the following temperatures 680° F. (410° C.), 710° F. (426° C.),730° F. (438° C.), 740° F. (443° C.), 760° F. (454° C.), and 760° F.(454° C.) to form one of several foamed articles including an extrudedprofile such as used for separators, wire insulation, or jackets forcabling.

The foamed articles were found to possess an outstanding cellsstructure, with tunable foaming level, and outstanding insulatingproperties as described in the following example.

Example 12 PEEK

A tape cable support-separator was manufactured with a 1.5 inch hightemperature extruder using the following materials and conditions:

A tape die with a high compression screw, a line speed of 192 ft./min.,with a 40 RPM screw speed and a melt temperature of 649° F. (343° C.)was used. The extruder was loaded with a pellet master batch, the pelletcomprising 7.5% talc, 0.25% Aclyn® wax or Genioplast Silicone or DowCorning Si Powder Resin, halogen-free, powdered siloxane, Dow Corning4-7105 or 4-7081 and 82.25% PEI. The pellet master batch was not blendeddown, but rather was used at 100%. This resulted in an extruded tapethat was 45% foamed with an average foamed cell size of 0.0007 inches.

Example 13 PPSU

Manufacture of a Pelletized Foamable Composition

A mixture of a non-halogenated resin, namely PPSU, talc and Aclyn® waxor Genioplast Silicone or Dow Corning Si Powder Resin, halogen-free,powdered siloxane, Dow Corning 4-7105 or 4-7081 in a weight ratio ofAclyn® wax or Genioplast Silicone or Dow Corning Si Powder Resin,halogen-free, powdered siloxane, Dow Corning 4-7105 or4-7081/talc/non-halogenated resin 0.25/7.5/92.25 was formed bysequential additions through feeder section of a twin screw extruder.Temperature profile in the melt twin screw extruder was the following(from zone 1 to 11): 475° F., 550° F. (228° C.), 550° F. (228° C.), 550°F. (228° C.), 525° F. (274° C.), 480° F. (249° C.), 525° F. (274° C.),500° F. (260° C.), 500° F. (260° C.), 500° F. (260° C.), 575° F. (302°C.). The extruder was equipped with a pelletizer to produce pellets to ashape that is preferable for extrusion processes.

Example 14 PPSU

Manufacture of a PEI, Wax, and Talc Derivative (Masterbatch Composition)

Aclyn® wax or Genioplast Silicone or Dow Corning Si Powder Resin,halogen-free, powdered siloxane, Dow Corning 4-7105 or 4-7081commercially available from M. F. Cachat and a talc derivative ofchemical composition Mg3Si4O10(OH) was melt compounded with anon-halogenated resin, namely PPSU, in a weight ratio of Aclyn® wax orGenioplast Silicone or Dow Corning Si Powder Resin, halogen-free,powdered siloxane, Dow Corning 4-7105 or 4-7081/talc/non-halogenatedresin 0.25/15.0/84.75, in a twin screw extruder, with the followingtemperature profile: 475° F., 550° F. (228° C.), 550° F. (228° C.), 550°F. (228° C.), 525° F. (274° C.), 480° F. (249° C.), 525° F. (274° C.),500° F. (260° C.), 500° F. (260° C.), 500° F. (260° C.), 575° F. (302°C.).

Example 15 PPSU

Manufacture of Foamed Articles from a Mixture of Pellets:

Pellets obtained from example 1 or pellets obtained from example 2,blended with PPSU at a weight ratio of 50/50, were placed in the hopperof a 24 to 1 ratio high temperature extruder with heat zones 1 through 6set at the following temperatures: 650° F. (393° C.), 660° F. (399° C.),680° F. (410° C.), 690° F. (415° C.), 715° F. (429° C.) and 715° F.(429° C.) to form one of several foamed articles including an extrudedprofile such as used for separators, wire insulation, or jackets forcabling.

The foamed articles were found to possess an outstanding cellsstructure, with tunable foaming level, and outstanding insulatingproperties as described in the following examples.

Example 16 PPSU

A tape cable support-separator was manufactured with a 1.5 inch hightemperature extruder using the following materials and conditions;

A tape die with a high compression screw, a line speed of 360 ft./min.,with a 20 RPM screw speed and a melt temperature of 707° F. (375° C.)was used. The extruder was loaded with a pellet master batch, the pelletcomprising 7.5% talc, 0.25% Aclyn® wax or Genioplast Silicone or DowCorning Si Powder Resin, halogen-free, powdered siloxane, Dow Corning4-7105 or 4-7081 and 82.25% PEI. The pellet master batch was not blendeddown, but rather was used at 100%. This resulted in an extruded tapethat was 54% foamed with an average foamed cell size of 0.0007 inches.

Example 17 PES/PESU

Manufacture of a Pelletized Foamable Composition

A of a non-halogenated resin, namely PES/PESU, talc and Aclyn® wax orGenioplast Silicone or Dow Corning Si Powder Resin, halogen-free,powdered siloxane, Dow Corning 4-7105 or 4-7081 in a weight ratio ofAclyn® wax or Genioplast Silicone or Dow Corning Si Powder Resin,halogen-free, powdered siloxane, Dow Corning 4-7105 or4-7081/talc/non-halogenated resin 0.25/7.5/92.25 was formed bysequential additions through feeder section of a twin screw extruder.Temperature profile in the melt twin screw extruder was the following(from zone 1 to 11): 475° F., 550° F. (228° C.), 550° F. (228° C.), 550°F. (228° C.), 525° F. (274° C.), 480° F. (249° C.), 525° F. (274° C.),500° F. (260° C.), 500° F. (260° C.), 500° F. (260° C.), 575° F. (302°C.). The extruder was equipped with a pelletizer to produce pellets to ashape that is preferable for extrusion processes.

Example 18 PES/PESU

Manufacture of a PEI, Wax, and Talc Derivative (Masterbatch Composition)

Aclyn® wax or Genioplast Silicone or Dow Corning Si Powder Resin,halogen-free, powdered siloxane, Dow Corning 4-7105 or 4-7081commercially available from M. F. Cachat and a talc derivative ofchemical composition Mg3Si4O10(OH) was melt compounded with anon-halogenated resin, namely PES/PESU, in a weight ratio of Aclyn® waxor Genioplast Silicone or Dow Corning Si Powder Resin, halogen-free,powdered siloxane, Dow Corning 4-7105 or 4-7081/talc/non-halogenatedresin 0.25/15.0/84.75, in a twin screw extruder, with the followingtemperature profile: 475° F., 550° F. (228° C.), 550° F. (228° C.), 550°F. (228° C.), 525° F. (274° C.), 480° F. (249° C.), 525° F. (274° C.),500° F. (260° C.), 500° F. (260° C.), 500° F. (260° C.), 575° F. (302°C.).

Example 19 PES/PESU

Manufacture of Foamed Articles from a Mixture of Pellets;

Pellets obtained from example 1 or pellets obtained from example 2,blended with PES/PESU at a weight ratio of 50/50, were placed in thehopper of a 24 to 1 ratio high temperature extruder with heat zones 1through 6 set at the following temperatures 635° F. (385° C.), 645° F.(390° C.), 655° F. (396° C.), 665° F. (401° C.), 680° F. (410° C.) and680° F. (410° C.) to form one of several foamed articles including anextruded profile such as used for separators, wire insulation, orjackets for cabling.

The foamed articles were found to possess an outstanding cellsstructure, with tunable foaming level, and outstanding insulatingproperties as described in the following examples.

Example 20 PES/PESU

A tape cable support-separator was manufactured with a 1.5 inch hightemperature extruder using the following materials and conditions;

A tape die with a high compression screw, a line speed of 290 ft./min.,with a 12 RPM screw speed and a melt temperature of 689° F. (365° C.)was used. The extruder was loaded with a pellet master batch, the pelletcomprising 7.5% talc, 0.25% Aclyn® wax or Genioplast Silicone or DowCorning Si Powder Resin, halogen-free, powdered siloxane, Dow Corning4-7105 or 4-7081 and 82.25% PEI. The pellet master batch was not blendeddown, but rather was used at 100%. This resulted in an extruded tapethat was 58% foamed with an average foamed cell size of 0.0007 inches.

Example 21 PEI

Manufacture of a Pelletized Foamable Composition

A mixture of a non-halogenated resin, namely PEI, talc and Aclyn® wax orGenioplast Silicone or Dow Corning Si Powder Resin, halogen-free,powdered siloxane, Dow Corning 4-7105 or 4-7081 in a weight ratio ofAclyn® wax or Genioplast Silicone or Dow Corning Si Powder Resin,halogen-free, powdered siloxane, Dow Corning 4-7105 or4-7081/talc/non-halogenated resin 0.25/7.5/92.25 was formed bysequential additions through feeder section of the twin screw extruder.Temperature profile in the melt twin screw extruder was the following(from zone 1 to 11): 475° F., 550° F. (228° C.), 550° F. (228° C.), 550°F. (228° C.), 525° F. (274° C.), 480° F. (249° C.), 525° F. (274° C.),500° F. (260° C.), 500° F. (260° C.), 500° F. (260° C.), 575° F. (302°C.). The extruder was equipped with a pelletizer to produce pellets to ashape that is preferable for extrusion processes.

Example 22 PEI

Manufacture of a PEI, Wax, and Talc Derivative (Masterbatch Composition)

Aclyn® wax or Genioplast Silicone or Dow Corning Si Powder Resin,halogen-free, powdered siloxane, Dow Corning 4-7105 or 4-7081commercially available from M. F. Cachat and a talc derivative ofchemical composition Mg₃Si₄O₁₀(OH) was melt compounded with anon-halogenated resin, namely PEI, in a weight ratio of Aclyn® wax orGenioplast Silicone or Dow Corning Si Powder Resin, halogen-free,powdered siloxane, Dow Corning 4-7105 or 4-7081/talc/non-halogenatedresin 0.25/15.0/84.75, in a twin screw extruder, with the followingtemperature profile: 475° F., 550° F. (228° C.), 550° F. (228° C.), 550°F. (228° C.), 525° F. (274° C.), 480° F. (249° C.), 525° F. (274° C.),500° F. (260° C.), 500° F. (260° C.), 500° F. (260° C.), 575° F. (302°C.).

Example 23 PEI

Manufacture of Foamed Articles from a Mixture of Pellets;

Pellets obtained from example 1 or pellets obtained from example 2,blended with PEI at a weight ratio of 50/50, were placed in the hopperof a 24 to 1 ratio high temperature extruder with heat zones 1 through 5set at the following temperatures 560° F. (293° C.), 600° F. (316° C.),630° F. (332° C.), 625° F. (329° C.), and 620° F. (327° C.) to form oneof several foamed articles including an extruded profile such as usedfor separators, wire insulation, or jackets for cabling.

The foamed articles were found to possess an outstanding cell structure,with tunable foaming level, and outstanding insulating properties asdescribed in the following examples.

Example 24 PEI

A tape cable support-separator was manufactured with a 1 inch hightemperature extruder using the following materials and conditions;

A tape die with a high compression screw, a line speed of 125 ft./min.,with a 10 RPM screw speed and a melt temperature of 570° F. (300° C.)was used. The extruder was loaded with a pellet master batch, the pelletcomprising 7.5% talc by weight, 0.25% Aclyn® wax or Genioplast Siliconeor Dow Corning Si Powder Resin, halogen-free, powdered siloxane, DowCorning 4-7105 or 4-7081 by weight and 82.25% PEI by weight. The pelletmaster batch was not blended down, but rather was used at 100%. Thisresulted in an extruded tape that was 22% foamed with an average foamedcell size of 0.0007 inches.

Example 25 LCP

Manufacture of a Pelletized Foamable Composition

A non-halogenated resin, namely LCP, talc and Aclyn® wax or GenioplastSilicone or Dow Corning Si Powder Resin, halogen-free, powderedsiloxane, Dow Corning 4-7105 or 4-7081 in a weight ratio of Aclyn® waxor Genioplast Silicone or Dow Corning Si Powder Resin, halogen-free,powdered siloxane, Dow Corning 4-7105 or 4-7081/talc/non-halogenatedresin 0.25/7.5/92.25 was formed by sequential additions through feedersection of the twin screw extruder. Temperature profile in the melt twinscrew extruder was the following (from zone 1 to 11): 475° F., 550° F.(228° C.), 550° F. (228° C.), 550° F. (228° C.), 525° F. (274° C.), 480°F. (249° C.), 525° F. (274° C.), 500° F. (260° C.), 500° F. (260° C.),500° F. (260° C.), 575° F. (302° C.). The extruder was equipped with apelletizer to produce pellets to a shape that is preferable forextrusion processes.

Example 26 LCP

Manufacture of a PEI, Wax, and Talc Derivative (Masterbatch Composition)

Aclyn® wax or Genioplast Silicone or Dow Corning Si Powder Resin,halogen-free, powdered siloxane, Dow Corning 4-7105 or 4-7081commercially available from M. F. Cachat and a talc derivative ofchemical composition Mg₃Si₄O₁₀(OH) was melt compounded with anon-halogenated resin, namely LCP, in a weight ratio of Aclyn® wax orGenioplast Silicone or Dow Corning Si Powder Resin, halogen-free,powdered siloxane, Dow Corning 4-7105 or 4-7081/talc/non-halogenatedresin 0.25/15.0/84.75, in a twin screw extruder, with the followingtemperature profile: 475° F., 550° F. (228° C.), 550° F. (228° C.), 550°F. (228° C.), 525° F. (274° C.), 480° F. (249° C.), 525° F. (274° C.),500° F. (260° C.), 500° F. (260° C.), 500° F. (260° C.), 575° F. (302°C.).

Example 27 LCP

Manufacture of Foamed Articles from a Mixture of Pellets:

Pellets obtained from example 1 or pellets obtained from example 2,blended with LCP at a weight ratio of 50/50, were placed in the hopperof a 24 to 1 ratio high temperature extruder with heat zones 1 through 5set at the following temperatures 520° F. (321° C.), 540° F. (332° C.),560° F. (343° C.), 570° F. (349° C.), and 560° F. (343° C.) to form oneof several foamed articles including an extruded profile such as usedfor separators, wire insulation, or jackets for cabling.

The foamed articles were found to possess an outstanding cell structure,with tunable foaming level, and outstanding insulating properties asdescribed in the following examples.

Example 28 LCP

A tape cable support-separator was manufactured with a 1 inch hightemperature extruder using the following materials and conditions:

A tape die with a high compression screw, a line speed of 48 ft./min.,with a 4 RPM screw speed and a melt temperature of 536° F. (280° C.) wasused. The extruder was loaded with a pellet master batch, the pelletcomprising 7.5% talc (weight), 0.25% (weight) Aclyn® wax or GenioplastSilicone or Dow Corning Si Powder Resin, halogen-free, powderedsiloxane, Dow Corning 4-7105 or 4-7081 and 82.25% (weight) PEI. Thepellet master batch was not blended down, but rather was used at 100%.This resulted in an extruded tape that was 39% foamed with an averagefoamed cell size of 0.0007 inches.

Example 29 PEKK

Manufacture of a Pelletized Foamable Composition

Admixture of a non-halogenated resin, namely PEKK, talc and Aclyn® waxor Genioplast Silicone or Dow Corning Si Powder Resin, halogen-free,powdered siloxane, Dow Corning 4-7105 or 4-7081 in a weight ratio ofAclyn® wax or Genioplast Silicone or Dow Corning Si Powder Resin,halogen-free, powdered siloxane, Dow Corning 4-7105 or4-7081/talc/non-halogenated resin 0.25/7.5/92.25 was formed bysequential additions through feeder section of the twin screw extruder.Temperature profile in the melt twin screw extruder was the following(from zone 1 to 11): 475° F., 550° F. (228° C.), 550° F. (228° C.), 550°F. (228° C.), 525° F. (274° C.), 480° F. (249° C.), 525° F. (274° C.),500° F. (260° C.), 500° F. (260° C.), 500° F. (260° C.), 575° F. (302°C.). The extruder was equipped with a pelletizer to produce pellets to ashape that is preferable for extrusion processes.

Example 30 PEKK

Manufacture of a PEI, Wax, and Talc Derivative (Masterbatch Composition)

Aclyn® wax or Genioplast Silicone or Dow Corning Si Powder Resin,halogen-free, powdered siloxane, Dow Corning 4-7105 or 4-7081commercially available from M. F. Cachat and a talc derivative ofchemical composition Mg₃Si₄O₁₀(OH) was melt compounded with anon-halogenated resin, namely PEKK, in a weight ratio of Aclyn® wax orGenioplast Silicone or Dow Corning Si Powder Resin, halogen-free,powdered siloxane, Dow Corning 4-7105 or 4-7081/talc/non-halogenatedresin 0.25/15.0/84.75, in a twin screw extruder, with the followingtemperature profile: 475° F., 550° F. (228° C.), 550° F. (228° C.), 550°F. (228° C.), 525° F. (274° C.), 480° F. (249° C.), 525° F. (274° C.),500° F. (260° C.), 500° F. (260° C.), 500° F. (260° C.), 575° F. (302°C.).

Example 31 PEKK

Manufacture of Foamed Articles from a Mixture of Pellets;

Pellets obtained from example 1 or pellets obtained from example 2,blended with PEKK at a weight ratio of 50/50, were placed in the hopperof a 24 to 1 ratio high temperature extruder with heat zones 1 through 5set at the following temperatures 520° F. (321° C.), 540° F. (332° C.),560° F. (343° C.), 570° F. (349° C.), and 560° F. (343° C.) to form oneof several foamed articles including an extruded profile such as usedfor separators, wire insulation, or jackets for cabling.

The foamed articles were found to possess an outstanding cellsstructure, with tunable foaming level, and outstanding insulatingproperties as described in the following examples.

Example 32 PEKK

A tape cable support-separator was manufactured with a 1.5 inch hightemperature extruder using the following materials and conditions;

A tape die with a high compression screw, a line speed of 48 ft./min.,with a 4 RPM screw speed and a melt temperature of 536° F. (280° C.) wasused. The extruder was loaded with a pellet master batch, the pelletcomprising 7.5% talc, 0.25% Aclyn® wax or Genioplast Silicone or DowCorning Si Powder Resin, halogen-free, powdered siloxane, Dow Corning4-7105 or 4-7081 and 82.25% PEI. The pellet master batch was not blendeddown, but rather was used at 100%. This resulted in an extruded tapethat was 39% foamed with an average foamed cell size of 0.0007 inches.

Example 33 PC

Manufacture of a Pelletized Foamable Composition

A mixture of a non-halogenated resin, namely PC, talc and Aclyn® wax orGenioplast Silicone or Dow Corning Si Powder Resin, halogen-free,powdered siloxane, Dow Corning 4-7105 or 4-7081 in a weight ratio ofAclyn® wax or Genioplast Silicone or Dow Corning Si Powder Resin,halogen-free, powdered siloxane, Dow Corning 4-7105 or4-7081/talc/non-halogenated resin 0.25/7.5/92.25 was formed bysequential additions through feeder section of the twin screw extruder.Temperature profile in the melt twin screw extruder was the following(from zone 1 to 11): 475° F., 550° F. (228° C.), 550° F. (228° C.), 550°F. (228° C.), 525° F. (274° C.), 480° F. (249° C.), 525° F. (274° C.),500° F. (260° C.), 500° F. (260° C.), 500° F. (260° C.), 575° F. (302°C.). The extruder was equipped with a pelletizer to produce pellets to ashape that is preferable for extrusion processes.

Example 34 PC

Manufacture of a PEI, Wax, and Talc Derivative (Masterbatch Composition)

Aclyn® wax or Genioplast Silicone or Dow Corning Si Powder Resin,halogen-free, powdered siloxane, Dow Corning 4-7105 or 4-7081commercially available from M. F. Cachat and a talc derivative ofchemical composition Mg3Si4O10(OH) was melt compounded with anon-halogenated resin, namely PC, in a weight ratio of Aclyn® wax orGenioplast Silicone or Dow Corning Si Powder Resin, halogen-free,powdered siloxane, Dow Corning 4-7105 or 4-7081/talc/non-halogenatedresin 0.25/15.0/84.75, in a twin screw extruder, with the followingtemperature profile: 475° F., 550° F. (228° C.), 550° F. (228° C.), 550°F. (228° C.), 525° F. (274° C.), 480° F. (249° C.), 525° F. (274° C.),500° F. (260° C.), 500° F. (260° C.), 500° F. (260° C.), 575° F. (302°C.).

Example 35 PC

Manufacture of Foamed Articles from a Mixture of Pellets;

Pellets obtained from example 1 or pellets obtained from example 2,blended with PC at a weight ratio of 50/50, were placed in the hopper ofa 24 to 1 ratio high temperature extruder with heat zones 1 through 5set at the following temperatures 520° F. (321° C.), 540° F. (332° C.),560° F. (343° C.), 570° F. (349° C.), and 560° F. (343° C.) to form oneof several foamed articles including an extruded profile such as usedfor separators, wire insulation, or jackets for cabling.

The foamed articles were found to possess an outstanding cellsstructure, with tunable foaming level, and outstanding insulatingproperties as described in the following working examples;

Example 36 PC

A tape cable support-separator was manufactured with a 1.5 inch hightemperature extruder using the following materials and conditions;

A tape die with a high compression screw, a line speed of 48 ft./min.,with a 4 RPM screw speed and a melt temperature of 536° F. (280° C.) wasused. The extruder was loaded with a pellet master batch, the pelletcomprising 7.5% talc, 0.25% Aclyn® wax or Genioplast Silicone or DowCorning Si Powder Resin, halogen-free, powdered siloxane, Dow Corning4-7105 or 4-7081 and 82.25% PEI. The pellet master batch was not blendeddown, but rather was used at 100%. This resulted in an extruded tapethat was 39% foamed with an average foamed cell size of 0.0007 inches.

Example 37 PPE

Manufacture of a Pelletized Foamable Composition

A mixture of a non-halogenated resin, namely PPE, talc, and Aclyn® waxor Genioplast Silicone or Dow Corning Si Powder Resin, halogen-free,powdered siloxane, Dow Corning 4-7105 or 4-7081 in a weight ratio ofAclyn® wax or Genioplast Silicone or Dow Corning Si Powder Resin,halogen-free, powdered siloxane, Dow Corning 4-7105 or4-7081/talc/non-halogenated resin 0.25/7.5/92.25 was formed bysequential additions through feeder section of the twin screw extruder.Temperature profile in the melt twin screw extruder was the following(from zone 1 to 11): 475° F., 550° F. (228° C.), 550° F. (228° C.), 550°F. (228° C.), 525° F. (274° C.), 480° F. (249° C.), 525° F. (274° C.),500° F. (260° C.), 500° F. (260° C.), 500° F. (260° C.), 575° F. (302°C.). The extruder was equipped with a pelletizer to produce pellets to ashape that is preferable for extrusion processes.

Example 38 PPE

Manufacture of a PEI, Wax, and Talc Derivative (Masterbatch Composition)

Aclyn® wax or Genioplast Silicone or Dow Corning Si Powder Resin,halogen-free, powdered siloxane, Dow Corning 4-7105 or 4-7081commercially available from M. F. Cachat and a talc derivative ofchemical composition Mg₃Si₄O₁₀(OH) was melt compounded with anon-halogenated resin, namely PPE, in a weight ratio of Aclyn® wax orGenioplast Silicone or Dow Corning Si Powder Resin, halogen-free,powdered siloxane, Dow Corning 4-7105 or 4-7081/talc/non-halogenatedresin 0.25/15.0/84.75, in a twin screw extruder, with the followingtemperature profile: 475° F., 550° F. (228° C.), 550° F. (228° C.), 550°F. (228° C.), 525° F. (274° C.), 480° F. (249° C.), 525° F. (274° C.),500° F. (260° C.), 500° F. (260° C.), 500° F. (260° C.), 575° F. (302°C.).

Example 39 PPE

Manufacture of Foamed Articles from a Mixture of Pellets:

Pellets obtained from example 1 or pellets obtained from example 2,blended with PPE at a weight ratio of 50/50, were placed in the hopperof a 24 to 1 ratio high temperature extruder with heat zones 1 through 5set at the following temperatures 520° F. (321° C.), 540° F. (332° C.),560° F. (343° C.), 570° F. (349° C.), and 560° F. (343° C.) to form oneof several foamed articles including an extruded profile such as usedfor separators, wire insulation, or jackets for cabling.

The foamed articles were found to possess an outstanding cellsstructure, with tunable foaming level, and outstanding insulatingproperties as described in the following example.

Example 40 PPE

A tape cable support-separator was manufactured with a 1.5 inch hightemperature extruder using the following materials and conditions;

A tape die with a high compression screw, a line speed of 48 ft./min.,with a 4 RPM screw speed and a melt temperature of 536° F. (280° C.) wasused. The extruder was loaded with a pellet master batch, the pelletcomprising 7.5% talc, 0.25% Aclyn® wax or Genioplast Silicone or DowCorning Si Powder Resin, halogen-free, powdered siloxane, Dow Corning4-7105 or 4-7081 and 82.25% PEI. The pellet master batch was not blendeddown, but rather was used at 100%. This resulted in an extruded tapethat was 39% foamed with an average foamed cell size of 0.0007 inches.

The teachings of all patents, published applications and referencescited herein are incorporated by reference in their entirety.

While the preferred embodiments of the invention have been illustratedand described, it will be clear that the invention is not so limited.Numerous modifications, changes, variations, substitutions, andequivalents will occur to those skilled in the art without departingfrom the spirit and scope of the present invention as defined by theappended claims.

What is claimed is:
 1. An insulation for use with a cable configured tocarry at least one of electrical power and communication data, theinsulation comprising: a foamed polymeric material comprising aplurality of cellular structures, each comprising a maximum diameter ina range of about 0.0005 inches to about 0.003 inches, wherein the foamedpolymeric material comprises at least one of engineered resin,polyphenylenesulfide (PPS), polyetherimide (PEI), polysulfone (PSU),polyphenylsulfone (PPSU), polyethersulfone (PES/PESU),polyetheretherketone (PEEK), polyaryl etherketone (PAEK),polyetherketoneketone (PEKK), polyetherketone (PEK), polyolefins,polyethylene (PE), polypropylene (PP), cyclic olefin copolymer (COC),polycarbonate (PC), polyphenylene ether (PPE), liquid crystal polymer(LCP), and combinations thereof, wherein the foamed polymeric materialcomprises a foaming level ranging from about 20% to about 60%, about 20%to about 70%, or about 30% to about 60%, wherein the foamed polymericmaterial comprises a chemically foamed material, foamed using talc or atalc derivative, and wherein at least about 60%, at least about 70%, orat least about 80% of the cellular structure comprises closed cells. 2.The insulation of claim 1, further comprising a solid polymericmaterial, wherein the solid polymeric material comprises anon-halogenated polymer.
 3. The insulation of claim 1, wherein theinsulation has a thickness ranging from about 0.005 inches to about0.009 inches.
 4. The insulation of claim 1, wherein the insulationcomprises two or more layers of materials.
 5. The insulation of claim 4,wherein at least one layer of the two or more layers of materialscomprises at least one of a polymeric material comprising afluoropolymer, a foamed polymeric material, a non-halogenated polymer, aflame retardant material, a smoke suppressant additive, a solidpolymeric material, and a solid structure.
 6. The insulation of claim 5,wherein the fluoropolymer comprises at least one ofpolytetrafluoroethylene-perfluoromethylvinylether (MFA), fluorinatedethylene propylene (FEP), perfluoroalkoxy (PFA), polyvinyl fluoride(PVF), ethylene tetrafluoroethylene,poly(ethylene-co-tetrafluoroethylene), ethylene chlorotrifluoroethylene(ECTFE), polyvinylidene fluoride (PVDF), and a combination thereof. 7.The insulation of claim 1, wherein at least one of the plurality ofcellular structures comprises a size ranging from about 0.0005 inches toabout 0.003 inches.
 8. A cable jacket configured to surround internalelements of a cable configured to carry at least one of electrical powerand communications data, the cable jacket comprising: a foamed polymericmaterial comprising a plurality of cellular structures, each comprisinga maximum diameter in a range of about 0.0005 inches to about 0.003inches; wherein the foamed polymeric material comprises at least one ofengineered resin, polyphenylenesulfide (PPS), polyetherimide (PEI),polysulfone (PSU), polyphenylsulfone (PPSU), polyethersulfone(PES/PESU), polyetheretherketone (PEEK), polyaryl etherketone (PAEK),polyetherketoneketone (PEKK), polyetherketone (PEK), polyolefins,polyethylene (PE), polypropylene (PP), cyclic olefin copolymer (COC),polycarbonate (PC), polyphenylene ether (PPE), liquid crystal polymer(LCP), and combinations thereof, wherein the foamed polymeric materialcomprises a foaming level ranging from about 20% to about 60%, about 20%to about 70%, or about 30% to about 60%, wherein the foamed polymericmaterial comprises a chemically foamed material, foamed using talc or atalc derivative, and wherein at least about 60%, at least about 70%, orat least about 80% of the cellular structure comprises closed cells. 9.The cable jacket of claim 8, wherein the cable jacket comprises aninternal diameter equal to or less than about 0.4 inches.
 10. The cablejacket of claim 8, wherein the cable jacket comprises an internaldiameter ranging from about 0.24 inches to about 0.32 inches or fromabout 0.24 inches to about 0.27 inches.
 11. The cable jacket of claim 8,wherein the cable jacket comprises a thickness ranging from about 0.005inches to about 0.015 inches or about 0.007 inches to about 0.010inches.
 12. A cable comprising: one or more transmission mediaconfigured to carry at least one of electrical power and communicationsdata; an insulation material configured to at least partially cover atleast one transmission medium from among one or more transmission media;and a jacket surrounding the one or more transmission media and theinsulation material; wherein at least one of the insulation and thejacket comprises a foamed polymeric material comprising at least one ofengineered resin, polyphenylenesulfide (PPS), polyetherimide (PEI),polysulfone (PSU), polyphenylsulfone (PPSU), polyethersulfone(PES/PESU), polyetheretherketone (PEEK), polyaryl etherketone (PAEK),polyetherketoneketone (PEKK), polyetherketone (PEK), polyolefins,polyethylene (PE), polypropylene (PP), cyclic olefin copolymer (COC),polycarbonate (PC), polyphenylene ether (PPE), liquid crystal polymer(LCP), and combinations thereof, and wherein, the foamed polymericmaterial further comprising a plurality of cellular structures, eachcomprising a maximum diameter of about 0.0005 inches to about 0.003inches, wherein the foamed polymeric material comprises a foaming levelranging from about 20% to about 60%, about 20% to about 70%, or about30% to about 60%, wherein the foamed polymeric material comprises achemically foamed material, foamed using talc or a talc derivative, andwherein at least about 60%, at least about 70%, or at least about 80% ofthe cellular structure comprises closed cells.
 13. The cable of claim12, wherein at least one of said transmission media comprises at leastone electrical conductor capable of carrying both data and electricalpower.
 14. The cable of claim 13, wherein said at least one electricalconductor is capable of carrying electrical power in a range of about 1watt to about 30 watts.
 15. The cable of claim 13, wherein said at leastone electrical conductor is capable of carrying an electrical current ina range of about 1 milliamp to about 2 amperes.
 16. The cable of claim12, wherein two or more of said transmission media are capable ofcarrying collectively electrical power in a range of about 1 watt toabout 300 watts.
 17. The cable of claim 12, further comprising aseparator providing a plurality of channels for receiving said one ormore transmission media.
 18. The cable of claim 15, wherein saidseparator comprises a foamed polymeric material comprising anon-halogenated polymer.
 19. The cable of claim 15, wherein saidseparator comprises a central channel.
 20. The cable of claim 17,further comprising at least one optical fiber disposed in said centralchannel of the separator.